Remanufacturing method of process cartridge

[0002] The present invention relates to a remanufacturing method for a process cartridge.

[0003] Here, the process cartridge is a cartridge containing at least a developing roller as developing means and an electrophotographic photosensitive member as a unit, the cartridge being detachably mountable to a main assembly of an electrophotographic image forming apparatus.

[0004] The electrophotographic image forming apparatus is an apparatus in which an image is formed on a recording material (recording paper, textile or the like) using an electrophotographic image forming process, and includes an electrophotographic copying machine, an electrophotographic printer (an LED printer, a laser beam printer and so on), an electrophotographic printer-type facsimile machine, an electrophotographic word processor, and the like.

[0005] In an electrophotographic image forming apparatus using an electrophotographic image forming process, a process cartridge is used which integrally contains an electrophotographic photosensitive member and process means actable on the electrophotographic photosensitive member, the process cartridge being detachably mountable to the main assembly of the electrophotographic image forming apparatus. With this process-cartridge type, the maintenance of the apparatus can be carried out in effect without service people. Therefore, this process-cartridge type is widely used in the field of the electrophotographic image forming apparatus.

[0006] Such a process cartridge forms an image on recording material with toner. Therefore, the toner is consumed in accordance with image forming operations. When the toner is consumed to such an extent that the user is not satisfied with the image quality of the image produced by the process cartridge, the commercial value of the process cartridge is lost.

[0007] It is desired that such a used process cartridge is given commercial value again by remanufacturing the process cartridge through an easy method.

[0008] Accordingly, it is a principal object of the present invention to provide a remanufacturing method of a process cartridge.

[0009] It is another object of the present invention to provide a remanufacturing method of a process cartridge in which when the process cartridge is transported, the toner is prevented from leaking out.

[0010] It is a further object of the present invention to provide a remanufacturing method of a process cartridge, wherein the process cartridge with which the toner is consumed to such an extent that the user is not satisfied with the image quality is recycled to be given a commercial value.

[0011] According to an aspect of the present invention, there is provided a remanufacturing method of remanufacturing a process cartridge comprising:

[0012] (a) a step of preparing a used process cartridge which comprises a toner developing container, a cleaning container and pins for coupling the toner developing container and the cleaning container at opposite longitudinal ends of the process cartridge,

[0013] the toner developing container including a toner accommodating portion, a toner supply opening, a developing roller and a developing blade;

[0014] the cleaning container including an electrophotographic photosensitive drum;

[0015] (b) a container separating step of separating the process cartridge into the toner developing container and the cleaning container by disengaging the pins from the process cartridge;

[0016] (c) a developing roller dismounting step of dismounting the developing roller from the toner developing container separated by the container separating step;

[0017] (d) a developing blade dismounting step of dismounting the developing blade from the toner developing container separated by the container separating step;

[0018] (e) a sealing material filling step of filling a sealing material into a gap formed in the toner developing container extending longitudinally inside of an end seal provided at each of longitudinally opposite ends thereof;

[0019] (f) a developing blade mounting step of mounting the developing blade on the toner developer container having the sealing material;

[0020] (g) a developing roller mounting step of mounting the developing roller on the toner developer container having the sealing material;

[0021] (h) a toner refilling step of refilling the toner into the toner accommodating portion of the toner developing container having the sealing material, the developing blade and the developing roller; and

[0022] (i) a container coupling step of coupling the toner developing container having the sealing material, the developing blade and the developing roller with the cleaning container by engaging the pin into them.

[0023] According to another aspect of the present invention, there is provided a remanufacturing method of remanufacting a process cartridge comprising:

[0024] (a) a step of preparing a used process cartridge which comprises a toner developing container, a cleaning container and pins for coupling the toner developing container and the cleaning container at opposite longitudinal ends of the process cartridge,

[0025] the toner developing container including a toner accommodating portion, a toner supply opening, a developing roller and a developing blade;

[0026] the cleaning container including an electrophotographic photosensitive drum;

[0027] (b) a container separating step of separating the process cartridge into the toner developing container and the cleaning container by disengaging the pins from the process cartridge;

[0028] (c) a developing roller dismounting step of dismounting the developing roller from the toner developing container separated by the container separating step;

[0029] (d) a developing blade dismounting step of dismounting the developing blade from the toner developing container separated by the container separating step;

[0030] (e) a sealing material filling step of filling a sealing material into a gap formed in the toner developing container extending longitudinally inside of an end seal provided at each of longitudinally opposite ends thereof;

[0031] (f) a sealing material applying step of applying a sealing material to cover a portion of a sealing member exposed from the toner developing container, the sealing member being the provided at each of the opposite longitudinal ends at a position remote from the developing roller;

[0032] (g) a developing blade mounting step of mounting the developing blade on the toner developer container having the sealing material;

[0033] (h) a developing roller mounting step of mounting the developing roller on the toner developer container having the sealing material;

[0034] (i) a toner refilling step of refilling the toner into the toner accommodating portion of the toner developing container having the sealing material, the developing blade and the developing roller; and

[0035] (j) a container coupling step of coupling the toner developing container having the sealing material, the developing blade and the developing roller with the cleaning container by engaging the pins into them.

[0036] These and other objects, features and advantages of the present invention will become more apparent upon a consideration of the following description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawings.

[0037] FIG. 1 is a longitudinal sectional view of an electrophotographic image forming apparatus.

[0038] FIG. 2 is a longitudinal sectional view of an electrophotographic image forming apparatus.

[0039] FIG. 3 is a perspective view of an electrophotographic image forming apparatus.

[0040] FIG. 4 is a longitudinal sectional view of a process cartridge.

[0041] FIG. 5 is a perspective view of a process cartridge.

[0042] FIG. 6 is a side view of a process cartridge.

[0043] FIG. 7 is a partly broken side view of a process cartridge.

[0044] FIG. 8 is a top plan view of a frame of a toner developing container.

[0045] FIG. 9 is a side view of a drum shutter.

[0046] FIG. 10 is a top plan view of a process cartridge.

[0047] FIG. 11 is an exploded perspective view of a toner developing container and a cleaner container.

[0048] FIG. 12 is a developed schematic view of a cleaner container.

[0049] FIG. 13 is a horizontal sectional view of a toner developing container.

[0050] FIG. 14 is a perspective view of a toner developing container without a developing roller.

[0051] FIG. 15 is an exploded perspective view of supporting means for the developing roller.

[0052] FIG. 16 is an exploded perspective view of a toner developing container.

[0053] FIG. 17 is a top plan view of a toner developing container from which the developing roller and the developing blade have been removed.

[0054] FIG. 18 is an enlarged review of part E in FIG. 17.

[0055] FIG. 19 is an enlarged view of part F of FIG. 17.

[0056] FIG. 20 is a front view of a toner developing container as seen in the direction opposite from the mounting direction of the process cartridge.

[0057] FIG. 21 is a longitudinal sectional view of a process cartridge.

[0058] FIG. 22 is a side view of a process cartridge.

[0059] FIG. 23 is a side view of a process cartridge.

[0060] FIG. 24 is a side view of a toner developing container.

[0061] FIG. 25 is a side view of a toner developing container.

[0062] FIG. 26 is a longitudinal sectional view of a connecting portion between the toner developing container and the cleaner container.

[0063] FIG. 27 is a perspective view of a toner developing container and a cleaner container.

[0064] FIG. 28 is a top plan view of a toner developing container.

[0065] FIG. 29 is a perspective view of a cleaning blade.

[0066] FIG. 30 is a front view illustrating a sealing step for a cutaway portion.

[0067] FIG. 31 is a top plan view of the device shown in FIG. 30.

[0068] FIG. 32 is a side view of the device shown in FIG. 30.

[0069] FIG. 33 is a front view of a side pad.

[0070] FIG. 34 is a side view after the side cover seal is mounted.

[0071] FIG. 35 is a top plan view of an end lateral seal.

[0072] FIG. 36 is a front view showing a disposition of the end lateral seal.

[0073] FIG. 37 is a front view showing mounting of a FIG. 37 groove filling seal.

[0074] FIG. 38 is a side view of the FIG. 38 groove filling seal.

[0075] FIG. 39 is a perspective view of the FIG. 39 groove filling seal.

[0076] FIG. 40 is a top plan view illustrating mounting of the FIG. 40 groove filling seal.

[0077] FIG. 41 is a side view of the device shown in FIG. 40.

[0078] FIG. 42 is a side view illustrating the positional relationship between the FIG. 42 groove filling seal and the seal.

[0079] FIG. 43 is a top plan view illustrating a positional relationship between the FIG. 43 groove filling seal and the jaw seal.

[0080] FIG. 44 is a front view of a developing roller at a longitudinal end of the toner developing container as seen from the lower side.

[0081] FIG. 45 is a longitudinal sectional view of an end seal portion.

[0082] FIG. 46 is a top plan view of a toner developing container.

[0083] FIG. 47 is a longitudinal sectional view of a support structure for the photosensitive drum.

[0084] FIG. 48 is a side view of a support structure for the charging roller.

[0085] FIG. 49 is a longitudinal sectional view of a cleaning device for a cleaner container.

[0086] FIG. 50 is a perspective view of a nozzle of the cleaning device.

[0087] FIG. 51 is a flow chart of the cleaning function.

[0088] FIG. 52 is a perspective view of the photosensitive drum and the developing roller during image forming operation.

[0089] FIG. 53 is a longitudinal sectional view of the process cartridge during the transportation thereof.

[0090] FIG. 54 is a perspective view illustrating the relationship between the photosensitive drum and the charging roller during transportation of the process cartridge.

[0091] FIG. 55 is a perspective view of a process cartridge during transportation thereof.

[0092] FIG. 56 is a longitudinal sectional view of a toner filling according to a further embodiment of the present invention.

[0093] FIG. 57 is a longitudinal sectional view of a toner filling according to a further embodiment of the present invention.

[0094] FIG. 58 is a longitudinal sectional view of an electrophotographic image forming apparatus.

[0095] FIG. 59 is a perspective view of an electrophotographic image forming apparatus.

[0096] FIG. 60 is a longitudinal sectional view of a process cartridge.

[0097] FIG. 61 is a perspective view of a process cartridge.

[0098] FIG. 62 is a side view of a process cartridge.

[0099] FIG. 63 is a partly broken side view of a process cartridge.

[0100] FIG. 64 is a plan view of a frame constituting a toner developing container.

[0101] FIG. 65 is a side view of a drum shutter.

[0102] FIG. 66 is a plan view of a process cartridge.

[0103] FIG. 67 is an exploded perspective view of a toner developing container and a cleaner container.

[0104] FIG. 68 is a schematic developed view of a cleaner container.

[0105] FIG. 69 is a horizontal sectional view of a toner developing container.

[0106] FIG. 70 is a perspective view of a toner developing container without a developing roller.

[0107] FIG. 71 is an exploded perspective view of a supporting means for supporting a developing roller.

[0108] FIG. 72 is an exploded perspective view of a toner developing container.

[0109] FIG. 73 is a top plan view of a toner developing container without the developing roller and the developing blade.

[0110] FIG. 74 is an enlarged view of part E shown in FIG. 48.

[0111] FIG. 75 is an enlarged view of part F shown in FIG. 48.

[0112] FIG. 76 is a front view of a toner developing container as seen in the direction opposite from the process cartridge mounting direction.

[0113] FIG. 77 is a longitudinal sectional view of a process cartridge.

[0114] FIG. 78 is a side view of a process cartridge.

[0115] FIG. 79 is a side view of a process cartridge.

[0116] FIG. 80 is a side view of a toner developing container.

[0117] FIG. 81 is a side view of a toner developing container.

[0118] FIG. 82 is a longitudinal sectional view illustrating a connecting portion between the toner developing container and the cleaner container.

[0119] FIG. 83 is a perspective view of a cleaner container and a toner developing container.

[0120] FIG. 84 is a top plan view of a toner developing container.

[0121] FIG. 85 is a perspective view of a cleaning blade.

[0122] FIG. 86 is a front view illustrating a sealing step for a cut-away portion.

[0123] FIG. 87 is a sectional view taken along a line A—A FIG. 86.

[0124] FIG. 88 is a sectional view taken long a line B—B of FIG. 86.

[0125] FIG. 89 is a front view of a side pad.

[0126] FIG. 90 is a cross-section of the end seal portion.

[0127] FIG. 91 is a front view of a side cover seal.

[0128] FIG. 92 is a front view of an end of a blade bottom seal.

[0129] FIG. 93 is a longitudinal sectional view of a blade bottom seal portion.

[0130] FIG. 94 is a plan view of a jaw seal, a free seal and an end seal.

[0131] FIG. 95 is a top plan view of a free seal.

[0132] FIG. 96 is a top plan view of a toner developing container.

[0133] FIG. 97 is a perspective view of a photosensitive drum and a developing roller during an image forming operation.

[0134] FIG. 98 is a perspective view showing the relationship between the photosensitive drum and the charging roller during transportation of the process cartridge.

[0135] FIG. 99 is a longitudinal sectional view of a process cartridge during the transportion thereof.

[0136] FIG. 100 is a perspective view of a process cartridge during the transportation thereof.

[0137] FIG. 101 is a longitudinal sectional view illustrating a toner filling step according to an embodiment of the present intention.

[0138] FIG. 102 is a perspective view of an end of a developing roller illustrating a seal structure.

[0139] The preferred embodiments of the present invention will be described in conjunction with the accompanying drawings.

[0140] A description will be provided first as to the general arrangements of an image forming apparatus and a process cartridge according to an embodiment of the present invention and then as to the manufacturing method of the process cartridge. A description will be provided then as to the steps of disassembling and re-assembling of the process cartridge and as to the reassembled process cartridge.

[0141] The remanufacturing of the process cartridge from which the toner has been used up is disassembled into the toner developing container and the cleaner container, and the toner developing container is partly disassembled, and they are reassembled to provide a process cartridge having the toner developing container which is similar in function to the new process cartridge but has a partly different structure from the new process cartridge.

[0142] Referring to FIGS. 1 to 5, a description will be provided as to the process cartridge and an image forming apparatus to which the process cartridge is detachably mountable. A description will be provided as to the general arrangements of the process cartridge in the image forming apparatus, and then as to the structure of the cartridge frames and then as to the coupling of the frames.

[0143] (General Arrangement)

[0144] The image forming apparatus in this embodiment is an electrophotographic image forming apparatus (laser beam printer) A, as shown in FIG. 1, wherein an electrophotographic photosensitive member in the form of a drum is exposed to information light modulated in accordance with image information from an optical system 1, so that a latent image is formed on the photosensitive member, and the latent image is developed into a toner image. In synchronism with the formation of the toner image, the recording material 2 is fed out, one by one, from a sheet feeding cassette 3ausing a pick-up roller 3band separation claws 3cpress-contacted at the corners of the top surface of the recording material 2, and the sheet is fed by feeding means 3 including a feeding path 3dand a pair of registration rollers. The toner image formed on the electrophotographic photosensitive member in the process cartridge B is transferred onto the recording material 2 by applying a voltage to transfer means in the form of a transfer roller 4, and then the recording material 2 is fed to fixing means 5 on a feeding path 3f.The fixing means 5 comprises a driving roller 5aand a fixing roller 5ccontaining a heater 5btherein, and pressure and heat are imparted to the recording material 2 which is passing therethrough, by which the transferred toner image is fixed on the recording material. The recording material 2 is further fed by discharging rollers, and is discharged to a discharging portion 6 through a reverse feeding path.

[0145] On the other hand, the process cartridge B contains the electrophotographic photosensitive member and at least one process means. Here, the process means includes charging means for electrically charging the electrophotographic photosensitive member, developing means for developing a latent image formed on the electrophotographic photosensitive member, and cleaning means for cleaning the surface of the electrophotographic photosensitive member to remove residual toner. As shown in FIG. 4, in the process cartridge B of this embodiment, the electrophotographic photosensitive member in the form of an electrophotographic photosensitive drum 7 having a photosensitive layer is rotated, and a voltage is applied on the charging roller 8, which is the charging means, so that the surface of the photosensitive drum 7 is uniformly charged, and the photosensitive drum 7 is exposed to light image from the optical system 1 through an opening 9, by which an electrostatic latent image is formed, and the image is developed by developing means 10.

[0146] In the developing means 10, the toner in a toner accommodating portion 10ais fed out by feeding means in the form of a rotatable toner feeding member 10b, and a developing roller 10dcontaining therein a stationary magnet is rotated, by which a layer of toner particles triboelectrically charged by the developing blade 10eis formed on the surface of the developing roller 10d. The toner is selectively transferred onto the photosensitive drum 7 so that a toner image is formed. The developing roller 10dfunctions to supply the toner to the photosensitive drum 7. The developing blade 10efunctions to regulate the thickness of the toner layer on the surface of the developing roller 10d.

[0147] The transfer roller 4 is supplied with a voltage having a polarity opposite from the polarity of the toner image, by which the toner image is transferred onto the recording material 2. Thereafter, the residual toner remaining on the photosensitive drum 7 is scraped off by the cleaning blade 11a,and the removed toner is received by a receptor sheet 11b,and the received toner is collected into a removed toner accommodating portion 11c.

[0148] (Cartridge Mounting Means)

[0149] Various parts, such as the photosensitive drum 7, are supported and accommodated in a cartridge frame, which is provided by coupling the toner developing container 12 and the cleaner container 13. The cartridge is mounted to the main assembly 14 of the apparatus.

[0150] In the cartridge mounting means, when the cover member 15 is opened by rotating it about the shaft 15a(FIGS. 1, 2), there are guide grooves 16, which are inclined toward the rear side at each of the left and right sides of the cartridge mounting space, as shown in FIG. 2. The guide grooves 16 are disposed substantially symmetrically. The guide groove 16 is substantially linear. At the inlet side of the guide groove 16, there is provided a positioning portion 16c(main assembly side positioning portion 16c).

[0151] On the other hand, at the opposite outer ends of the process cartridge, there are provided guide portions corresponding to the guide grooves 16 to be guided by the guide grooves 16. The guide portions are projected substantially symmetrically at the opposite longitudinal ends, respectively. As shown in FIG. 5, it comprises a boss 18 and a rib 19, which are integral. The boss 18 and the rib 19 are Integrally formed with the cleaner container 13 to which the photosensitive drum 7 is mounted, and the boss 18 is disposed on an extension of a rotational axis of the photosensitive drum 7, and the rib 19 is extended from the boss 18 in an inserting direction of the process cartridge B as indicated by an arrow C in FIG. 5. The rib 19 extends inclined downwardly in conformity with the guide groove 16.

[0152] With this structure, when the process cartridge is to be mounted to the main assembly, as shown in FIG. 2, the cover member 15 is open, and the ribs 19 are engaged into the guide grooves 16, and then, the process cartridge B is inserted into the main assembly 14 of the apparatus. With the insertion, the process cartridge B makes a transnational motion, that is, linear motion inclined downward. When the process cartridge B is further inserted, the boss 18 of the process cartridge B is seated on the main assembly side positioning portion 16cin the inlet of the guide groove 16. Simultaneously, the free end 19aof the rib 19 abuts a stopper surface 16aof the guide groove 16 by a moment about the boss 18 produced by the weight of the process cartridge B. The gravity center of the process cartridge B is at the rib 19 side of the boss 18. Thus, the drum gear 51a(FIG. 5) fixed to an end of the photosensitive drum 7 is brought into meshing engagement with a driving gear 22 (FIG. 2) provided in the main assembly 14, so that a driving force can be transmitted to the process cartridge B.

[0153] Then, the cover member 15 is closed, by which the shutter opening lever 55, which is interrelated with the cover member, is rotated in the clockwise direction about the shaft 55cfrom a position 55ato a position 55b, so that it is engaged with a pin 28aprovided on the drum shutter member 28 as shown in FIG. 10, and the drum shutter member 28 is opened about a pin 29 mounted to the cleaner container 13 against a spring force of a spring 27, thus opening a transfer opening 13n. The coil spring 27 is fitted around the pin 29, and one end thereof is engaged to the cleaner container 13, and the other end is engaged to the drum shutter member 28, and therefore, when the cover member 15 is open or when the process cartridge B is outside the main assembly 14, the drum shutter member 28 closes the transfer opening 13nby the spring force of the coil spring 27.

[0154] When the process, cartridge B is to be taken out, the cover member 15 is opened, which the shutter opening lever 55 is rotated about the shaft 55cto return from the position 55bto the position 55a. Then, drum shutter member 28 rotates about the pin 29 by the spring force of the coil spring 27, thus closing the transfer opening 13n. The process cartridge B is pulled up such that the boss 18 is away from the positioning portion 16c, and thereafter, the process cartridge B is further pulled up such that ribs 19 are guided by the guide grooves 16.

[0155] (Structure of Cartridge Frame)

[0156] A description will be provided as to the structure of the cartridge frame. The cartridge frame is made of polystyrol resin material by injection molding, and as shown in FIG. 4, a lower developing frame 12bis welded to a side of the developing device frame 12a, and a cap member 12cis welded to the upper portion. thus constituting a toner developing container 12. A cap member 13bis welded to a top of a cleaning frame 13ato constitute an integral cleaner container 13. Then, the cleaner container 13 is coupled with the toner developing container 12 to constitute a cartridge frame.

[0157] The developing device frame 12ais provided at an end thereof with a toner supply opening 12a1, as shown in FIGS. 13, 14, and is also provided at one longitudinal end with a toner filling opening 12a2. The developing device frame 12ais provided therein with a plurality of erected supporting members (not shown) in the longitudinal direction. The toner supply opening 12a1 permits the supply of the toner from the toner accommodating portion 10ato the developing roller 10d. The toner in the toner accommodating portion 10ais supplied to the developing roller 10dthrough the toner supply opening 12a1.

[0158] When the developing means is mounted in place, as shown in FIGS. 4 and 13, a toner feeding member 10bis mounted in the developing device frame 12a, and thereafter, the cap member 12cis welded to the developing device frame 12a. Subsequently, a toner seal 31 in the form of a film is welded on a surface 12a5 of the seat formed around the circumference of the toner supply opening 12a1 of the toner developing container 12 to seal the opening 12a1. Then, the toner is filled through the toner filling opening 12a2, and thereafter, the filling opening 12a2 is plugged by a cap 32 to seal the toner accommodating portion 10a.The toner seal 31 sealing the toner supply opening 12a1, as shown in FIG. 13, is folded back at one longitudinal end of the opening 12a1, and the free end thereof is extended out through a slit 12a8 of the developing device frame 12a. The free end of the toner seal 31 is nipped by fingers of the user and is pulled out when the user starts use of the process cartridge B.

[0159] When it is pulled out, the sealing is not complete at the portion where the toner seal 31 extends through the toner developing container 12.

[0160] Therefore, as shown in FIG. 13, an elastic sealing material 10h,such a felt, is provided in the slit 12a8 at an end, closer to the free end, of the toner seal 31.

[0161] As shown in FIG. 13, the elastic sealing material 10his overlaid on the toner seal 31 and urges the toner seal 31. Therefore, when the toner seal 31 is pulled out, the elastic sealing material 10hoccupies the slit 12a8 which has been occupied by the toner seal 31 to be press-contacted to a wall of the developing device frame 12a, thus preventing leakage of the toner to the outside.

[0162] A description will be provided as to the mounting of the elastic sealing material 10h.As shown in FIG. 15, a part of the arcuate portion 12a6 of the developing device frame 12ais provided with an angle groove 12a26 extending in the longitudinal direction. The bottom of the angle groove 12a26 is flush with the toner seal sticking seat surface 12a5. An elastic sealing material 10h,such as a felt or the like, is stuck on a piece 10jengaged in the angle groove 12a26.

[0163] With this structure, even when the toner seal 31 is pulled out, the toner is prevented from leaking to the outside of the toner developing container 12 through the slit 12a8.

[0164] Then, the lower developing frame 12bis welded to the developing device frame 12a. As shown in FIG. 8, the developing device frame 12ais provided at the opposite longitudinal ends of the toner supply opening 12a1 with arcuate portions 12a6 at which the end seals 34 are to be mounted. A flat flange 12a16 extends between the arcuate portions 12a6 below the seal sticking seat surface 12a5, and the flange 12a16 is substantially perpendicular to the seal sticking seat surface 12a5. On the other hand, lower developing frame 12bis engaged with the longitudinally opposing surfaces of the arcuate portions 12a6. Therefore, in consideration of manufacturing errors, the lower developing frame 12bhas a length which is smaller than the distance between the opposing surfaces of the arcuate portion 12a6 by 2×g, where g is a gap at each of the ends. The flange 12a16 is provided with holes 12a17, and the lower developing frame 12bis provided with dowels 12b3 for engagement with the holes 12a17, respectively. With the dowels 12b3 being in engagement with the respective hole 12a17, the bottom surface of the lower developing frame 12band the top surface of the flange 12a16 of the developing device frame 12aare welded to each other. By doing so, gap g is formed between the arcuate portion 12a6 and the lower developing frame 12bat each end. The dimension of the gap g is not constant when the lower developing frame 12bis fixed to the developing device frame 12a.

[0165] When the lower developing frame 12bis engaged with the developing device frame 12a, a sealing material 39 such as a felt is inserted between the developing device frame 12aand each of the longitudinal opposite ends of the lower developing frame 12b.

[0166] Each of the opposite ends of the lower developing frame 12bis provided with an outward projection 12b2 (FIG. 8). The developing device frame 12ais provided at each of the end portions with a recess 12a18 for engagement with a projection 12b2 when the dowels 12b3 are engaged with the holes 12a17 for the purpose of welding or bonding of the lower developing frame 12b. As shown in FIG. 20, a gap g1 is provided between the recess 12a18 and the projection 12b2. The gap is substantially equal to the gap g formed between the lower developing frame 12band the arcuate portion 12a6.

[0167] As shown in FIG. 8, the arcuate portion 12a6 of the developing device frame 12ais provided with a sticking portion 12a20 to which the end seal 34 is stuck. The sticking portion 12a20 has an arcuate peripheral surface having a common axis with the arcuate portion 12a21 provided longitudinally outside of the arcuate portion 12a6. The axis is the rotational axis of the developing roller 10din the toner developing container 12. The sticking portion 12a20 is provided with an arcuate surface having a radius which is smaller than that of the outer arcuate portion 12a21. An end of the sticking portion 12a20, as shown in FIG. 8, ends short of (inside) the circumference of the outer arcuate portion 12a21.

[0168] As shown in FIGS. 17, 18, and 19, when the lower developing frame is welded to or bonded to the developing device frame 12a, a slit 12dis provided between the arcuate portion 12a6 and the lower developing frame 12b.

[0169] The slit 12d,as shown in FIGS. 21 to 23, is on an optical path of a laser beam passing through a gap (development gap) formed between the photosensitive drum 7 and the developing roller 10dprovided by the spacer roller 10d1, which is disposed to each of the opposite end portions of the photosensitive drum 7 and the developing roller 10d.The optical path passes through the slit 12d,a slit 10e6 provided in the metal blade 10e2 and a hole 13b1 formed in the cap member 13b.

[0170] In FIG. 21, the laser beam emitted from the laser source 86 has a width which is larger than the gap (approximately 300 μm) between the photosensitive drum 7 and the developing roller 10d. The laser beam emitted from the laser source 86 travels through the hole 13b1, the slit 10e6, the gap between the photosensitive drum 7 and the developing roller 10d, and the slit 12d, and is then received by a photoreceptor 87. The width of the laser beam received by the photoreceptor 87, is measured in a direction parallel with the face of the sheet of the drawing of FIG. 21. Therefore, the development gap can be detected.

[0171] The measurements of the gap between the photosensitive drum 7 and the developing roller 10dusing the laser beam, is effected at each of opposite longitudinal ends of the photosensitive drum 7 (two positions). Therefore, the hole 13b1, and the slits 10e6, 12dare each provided at at least two positions (adjacent opposite longitudinal ends).

[0172] After the lower developing frame 12bis welded to the developing device frame 12a, the end seal 34 and the seal 35 are mounted.

[0173] As shown in FIG. 16, the end seal 34 functions to provide a seal between the developing device frame 12aand each of the end portions of the developing blade 10eand each of the end portions of the developing roller 10d, and it comprises an arcuate portion 34acontactable to the developing roller 10dalong its circumferential surface and an integral linear portion 34balong a rear surface of each of the end portions of the metal blade 10e2. The outer circumference of the arcuate portion 34ais stuck to the sticking portion 12a20 of the developing device frame 12a.

[0174] As shown in FIG. 4, a seal 35 of urethane foam or the like is mounted and extended between blade mounting seat surfaces 12a4 formed above the toner discharging opening 12a1 of the toner discharging, and the developing blade 10eis screwed on the blade mounting seat surface 12a4 with the seal 35 therebetween. By doing so, the seal 35 is compressed between the metal blade 10e2 and a developing device frame 12aso that sealing is accomplished between the metal blade 10e2 and the developing device frame 12a.

[0175] The development holder 36 shown in FIGS. 16 and 24 is secured to one of the ends of the developing device frame 12a, and the development holder 37 shown in FIGS. 16 and 25 is secured to the other end thereof. The development holders 36, 37 are fixed to the developing device frame 12aby small screws 56, 57.

[0176] The shaft 10d2 of the developing roller 10dat one end is engaged with a fixed bearing 33bwhich is in the form of a shaft integral with the development holder 37 shown in FIGS. 15 and 16. The developing roller shaft 10d2 is received by a bearing hole 33a2 of the bearing 33aat the other end of the developing roller 10d, and as shown in FIG. 15, a hole 33a4 is engaged with a positioning dowel 12a7 provided on the developing device frame 12aat an outside of one of the longitudinal ends. Then, the developing roller gear 10fis engaged with the developing roller shaft 10d2. The engaging portion 33a3 of the bearing 33ais engaged with a part-cylindrical engaging portion 36aof the development holder 36. At this time, the developing roller gear 10fis accommodated in the development holder 36. A small screw 56 penetrates a hole 36cof the development holder 36, a hole 33a1 of the bearing 33aand is threaded into a female screw 12a13 of the developing device frame 12a. The gear accommodating portion 36boutside the development holder 36 is part-cylindrical, and when the toner developing container 12 and a cleaner container 13 are coupled, the developing roller gear 10fis brought into meshing engagement with the drum gear 51athrough the open part of the gear accommodating portion 36b.

[0177] Each of the development holders 36 and 37 is provided with an integral arm portion 38 functioning as a connecting portion for connecting the toner developing container 12 and the cleaner container 13.

[0178] The toner developing container 12 having the various members constituting the developing means and the cleaner container 13 having the various members constituting the photosensitive drum 7, the charging roller 8, and a cleaning means are coupled by the arm portions 38 to constitute the process cartridge B.

[0179] (Coupling between Toner Developing Container and Cleaner Container)

[0180] Referring to FIGS. 7, 11, 24, 25, and 26 a description will be provided as to the coupling between the toner developing container 12 and the cleaner container 13. FIGS. 7 and 11 are a side view and a perspective view, respectively, illustrating the coupling between the containers 12 and 13; FIG. 26 shows the inside of the coupling portion; and FIGS. 24 and 25 are side views of the copper end portion of the toner developing container 12. The containers 12, 13 are rotatably coupled through the arms 38 at the opposite ends. Since the covering structures at the left and right ends are substantially the same, a description will be provided as to only one end. However, the portions with a difference between the left and right hands will be described for the respective ends.

[0181] As shown in FIGS. 11 and 24, the developing device frame 12ais provided with an integral spring mounting portion 12a28, on which a compression coil spring 40 is mounted. The position of the compression coil spring 40 is adjacent one of the longitudinal ends of the developing device frame 12a, and is away from the arm portion 38 in a direction perpendicular to the longitudinal direction. The compression coil spring 40 extends out in parallel with the arm portion 38. At a free end portion of the arm portion 38 at a longitudinal end where the compression coil spring 40 is provided, a through-hole 38bis provided for receiving a pin 41, which will be described hereinafter. As shown in FIG. 26, an outer wall 13qof the cleaner container 13 is provided faith a hole 13cfor receiving the pin 41, and an inner wall 13dthereof is provided with a hole 13efor being press-fitted by the pin 41. The hole 13cand the hole 13eare aligned along a line parallel with the photosensitive drum 7. An elongated bore 38b1 is formed in the arm portion 38 and the other end of the cleaner container 13, and a line connecting the center of the elongated bore 38b1 and the hole 38bpasses through the centers of the holes 13c,13e. The elongated bore 38b1 is elongated in a direction parallel with a line connecting the center of the photosensitive drum 7 and the center of the developing roller 10d,and the width of the elongated bore 38b1 is equal to the diameter of the pin 41.

[0182] When the toner developing container 12 and the cleaner container 13 are coupled together with each other, as shown in FIGS. 7 and 11, the arm portion 38 of the toner developing container 12 is inserted into the recess 13hof the cleaner container 13, and the pin 41 penetrates through the hole 13c, 13cof the cleaner container 13, the through hole 38bof the arm portion 38, and the elongated bore 38b1 in the order named, and is press-fitted into the hole 13e, 13eof the inner wall 13d. By doing so, the toner developing container 12 and the cleaner container 13 are rotatably coupled for rotation about the pin 41. At this time, the compression coil spring 40 mounted to the developing device frame 12ais compressed by the abutment to the spring seat 13f(FIG. 26) of the cleaner container 13. The photosensitive drum 7 and the developing roller 10dare urged toward each other about the pin 41 so that spacer rollers 10d1 of the developing roller 10dare press-contacted to the photosensitive drum 7.

[0183] Because of the provision of the elongated bore 38b1, the photosensitive drum 7 and spacer rollers 10d1 of the developing roller 10dare contacted to each other at the generating lines thereof. The generating lines are parallel with the center lines of the photosensitive drum 7 and the developing roller 10d.

[0184] FIG. 7 shows an end surface portion that is opposite from the end where the compression coil spring 40 is provided. Opposite ends of a tension coil spring 59 are engaged with a spring hook 13pof the cleaner container 13 and a spring hook 12a29 of the developing device frame 12aof the toner developing container 12, respectively. The direction of the tension coil spring 59 is substantially parallel with a line connecting the centers of the photosensitive drum 7 and the developing roller 10d.

[0185] By the action of the compression coil spring 40 and the tension coil spring 59, the developing roller 10dmounted in the toner developing container 12 is urged toward the photosensitive drum 7 mounted in the cleaner container 13, so that spacer rollers 10d1 at the opposite longitudinal ends of the developing roller 10dcontact the photosensitive drum 7, by which the developing roller 10dis correctly positioned relative to the photosensitive drum 7. The drum gear 51afixed to the end of the photosensitive drum 7 is brought into meshing engagement with the developing roller gear 10ffixed to the end of the developing roller 10d,so that the driving force can be transmitted.

[0186] (Remanufacturing of Process Cartridge)

[0187] (Embodiment 1)

[0188] (Separating Step between Toner Developing Container and Cleaner Container)

[0189] The tension coil spring 59 shown in FIG. 7 is disengaged from the spring hook 13pof the cleaner container 13.

[0190] By doing so, the force between the photosensitive drum 7 and the developing roller 10dis provided only by the compression coil spring 40. Therefore, the toner developing container 12 and the cleaner container 13 are rotatable relative to each other about the pin 41.

[0191] Then, the pin 41 is removed. This is done by pulling out the pin 41 using a plyer or the like if the pin 41 is projected out of the process cartridge B. If not, the pin 41 is pushed into the process cartridge to disengage it.

[0192] Thus, the container separating step is completed, by which the toner developing container 12 comprising the toner accommodating portion 10a,the toner supply opening 12a1, the developing roller 10dand the developing blade 10e,and the cleaner container 13 comprising the photosensitive drum 7, are separated from each other by disengaging the pins 41 at one and the other longitudinal ends of the process cartridges B. FIG. 11 shows the thus separated toner developing container 12 and cleaner container 13.

[0193] (Removing Step of Developing Roller)

[0194] As shown in FIG. 28, the separated toner developing container 12 includes the developing roller 10dand the developing blade 10emounted thereto.

[0195] First, the development holders 36, 37 fixed to the opposite end of the developing device frame 12aare removed. The small screw 56 fastening the development holder 36 and the bearing 33ato the developing device frame 12a, as shown in FIG. 15, is removed, and the development holder 36 is moved longitudinally outwardly. Then, the developing roller gear 10fis pulled off the developing roller shaft 10d2. The bearing 33asupporting the developing roller 10dis removed from the shaft 10d2 of the developing roller 10d. The developing roller 10dis pulled in the actual direction to remove it from the bearing 33bof the development holder 37, and the developing roller 10dis removed from the toner developing container 12.

[0196] By doing so, the developing roller dismounting step is completed, by which the developing roller 10dmounted to the toner developing container 12 is removed. FIG. 14 shows a state in which the developing roller 10dhas been removed. When the gear train 61 (FIG. 25) for driving the toner feeding member 10bis to be inspected, the development holder 37 is removed from the developing device frame 12aby removing the small screw 57.

[0197] (Dismounting Step of Developing Blade)

[0198] After the developing roller 10dhas been removed, the developing blade 10eis removed. The developing blade 10eis removed by unthreading the small screws 10e4 which fix the developing blade 10eto the blade mounting seat surface 12a4 of the developing device frame 12aas shown in FIG. 14, and then moving the developing blade 10eaway from the blade mounting seat surface 12a4.

[0199] Thus, the developing blade dismounting step is completed, by which the developing blade 10emounted to the toner developing container 12 is separated by the separation step. FIG. 17 is a top plan view showing the toner developing device frame 12afrom which the developing blade 10ehas been removed. FIG. 29 shows the removed developing blade 10e(except for the side pad 65).

[0200] Here, all the elements that should be removed from the toner developing device frame 12ahave been removed. The drum shutter member 28 is not removed by this removal.

[0201] (Application of Sealing Material for Toner Developing Container)

[0202] If the toner seal 31 is restored, the remanufactured process cartridge is substantially the same as a new process cartridge. According to the invention, the toner seal 31 is not repaired or restored. Even without the toner seal 31, it will suffice if the toner does not leak when the developing means is mounted to the toner developing container.

[0203] (End Seal)

[0204] Each or one of the end seals 34 is replaced with a new one if it is confirmed as being damaged after inspection.

[0205] (Filling Sealing Material into Gap between Developing Device Frame and Lower Developing Frame)

[0206] Between the developing device frame 12aand the lower developing frame 12b, the gap g extends along the inner surface of the end seal 34 at each of the end portions. The gap g is in the form of a crank extending toward the gap g1 as shown in FIG. 20, as seen from an outside of the toner developing container 12.

[0207] First, the gaps g and g1 are sealed. This sealing is effected by continuously sticking a developing container cover side seal 62, which is an adhesive tape on an outer periphery of the lower developing frame 12band the arcuate portion 12a6 as shown in FIG. 20 (hatching line) and FIGS. 30 and 32. The sealing covers the entire length of the gaps g and g1 and also covers the slit 12d.

[0208] Then, the gap g is filled with a sealing material 64. The sealing material 64 is supplied from the inner side of the arcuate portion 12a6. When the sealing material 64 is filled into the gap g, the sealing material 64 is injected into the gap g at a position which is substantially at the middle of the length of the gap using a tool (unshown), and thereafter the sealing material 64 is expanded toward one and the other ends of the length of the gap g, thus filling the sealing material 64 into the gap g along its full length.

[0209] The sealing material 64 is plastically deformable. Examples of such sealing material 64 includes polymeric materials having a curing property or polymeric materials having a thermoplastic property. The sealing materials include a silicon bond which is a polymeric material having a silicone-bonding-material curing property. The polymeric material having a thermoplastic property includes hot melt plastic resin material.

[0210] When the silicon bond is used as the sealing material 64, for example, the sealing material is filled, and it is left for approximately 6 hours, and the cover side seal 62 is removed after it is dried.

[0211] (Sticking of Side Pad)

[0212] As shown in FIG. 33, a gap S exists between the longitudinal end of the elastic blade 10e1 of the developing blade 10eand the end seal 34. During the image forming operation, the toner does not leak out in the longitudinal direction by the provisions of the end seal 34 despite the existence of the gap S. However, during transportation, the toner is liable to leak out since the corner portion between the end seal 34 and a seal 35 is a linear portion 34bof the end seal 34 so that it is not in close contact with the developing roller 10d.Therefore, a side pad is provided.

[0213] As shown in FIG. 29, a side pad 65 (seal) is stuck on the longitudinal surface of the elastic blade 10e1 of the developing blade 10eat each of the opposite end portions so as to extend beyond the longitudinal end of the blade.

[0214] The pad is stuck on the backside of the elastic blade 10e1, that is, the side not facing to the developing roller 10d, using an adhesive material. The side pad 65 has such a size that it is compressed into the corner formed by the end seal 34 and a seal 35, so that it is contacted to them by its elasticity, and one side is substantially leveled with the free end of the elastic blade 10e1.

[0215] When the developing roller 10dis mounted, the side pad 65 provides sealing between the end seal 34 and the end of the elastic blade 10e1. The side pad 65 is press-contacted to the end seal 34 and to the seal 35.

[0216] By doing so, during transportation, the toner is prevented from leaking out through between the developing device frame 12aand the developing blade 10eat the opposite ends of the developing roller 10d.

[0217] The side pad 65 is mounted on the reused developing blade 10eif the developing blade 10eis reusable. When the developing blade 10eis to be replaced with a new part, the new part developing blade 10eis already provided with the side pad 65.

[0218] In this example, the side pad 65 is made of an elastic material such as a sponge.

[0219] (End Lateral Seal)

[0220] A jaw seal sticking seat surface 12b5 (FIG. 4) of the lower developing frame 12b, after a jaw seal (blow-preventing seal) 42 is stuck, is a flat surface, and an extension surface thereof is lower than the extension of the arcuate surface of the inner surface (the surface contacting to the developing roller 10d) of the arcuate portion 34aof the end seal 34. That is, the jaw seal sticking seat surface 12b5 is not flush with the upper surface of the end seal 34. Therefore, when the jaw seal 42 is stuck, a gap remains between the counterpart of the seal 42 at the longitudinal end thereof. The counterpart member is the sealing material 64 having sealed the gap g.

[0221] Therefore, an end lateral seal 66 of an elastic member is mounted against the end seal 34 provided at each of one and the other ends of the developing roller 10dat the longitudinally inside of the developing roller 10dand at the opposite side from the side where the toner accommodating portion 10ais provided.

[0222] FIG. 35 shows an end lateral seal developed into a plane. FIG. 36 is a sectional view taken along a line A—A. For the purpose of easy understanding, gaps are shown between members. Actually, however, the members shown in FIG. 36 are contacted without gaps. As shown in figure, the end lateral seal 66 is stuck to the lower developing frame 12bat the corners of the sealing material 64 and the end seal 34, by adhesive material. As will be described hereinafter, the jaw seal 42 is stuck usually first in the remanufacturing process. By doing so, the end lateral seal 66 is closely contacted to the end seal 34, the sealing material 64, and the lower developing frame 12b. The gap S1 among the jaw seal 42, the lower developing frame 12b, and an end lateral seal 66 is reduced by the side cover seal 69 and is sealed from the outside.

[0223] As shown in FIGS. 36 and 43, the opposite ends of the jaw seal 42 are overlaid on the end lateral seal 66 and the end seal 34.

[0224] With the above-described process, the sealing is provided between the jaw seal 42 and an end seal 34.

[0225] (Seal for Slit for Developing Gap Measurement)

[0226] As described in the foregoing, the toner sealing is quite completely accomplished by the sealing material 64, the side pad 65, the end lateral seal 66 and the seal 42. However, if the toner were passed through between the jaw seal 42 and the end lateral seal 66, the toner might reach the slit 12dprovided in order to assure the optical path for the measurement of the development gap. In view of this, a seal is provided to prevent the toner having reached the slit 12dfrom leaking out.

[0227] FIG. 37 is a front view of the cut-away portion constituting the slit 12das seen in a direction perpendicular to the longitudinal direction of a developing roller 10d.As shown in FIG. 38, the jaw groove filling seal 68 fills substantially the entire width of the cut-away portion 12d.

[0228] The process will be described. As shown in FIGS. 37, 40, and 41, a double-coated adhesive tape or the like is stuck on one surface 68bof a relatively thin rectangular sealing material 68a,and it is stuck on the end of the sealing material 64, the wool felt portion 34cof the end seal 34, and the bottom of the cut-away portion 12dsubstantially flush therewith. The end seal 34 comprises a felt portion 34cand a sliding portion 34dthereon, which is made of fibers having a small friction coefficient.

[0229] The sealing material 68ais bent by 90° from a corner AA where the arcuation of the arcuate portion 12a6 ends (FIG. 41) toward the outside, by which the slit 12dis substantially closed, as shown in FIG. 38. However, the complete closure of the slit is not intended. As shown in FIG. 41, if the upper portion of one surface 68bof the sealing material 68ais partly overlapped with the end of the end seal 34, the toner may pass through between the end lateral seal 66 and the jaw seal 42 to reach the slit 12d. It will suffice if the leakage of such toner is prevented, and therefore, as shown in FIG. 40, a gap g2 may be provided between the lateral wall 12d1 of the cut-away portion 12dand the sealing material (side cover seal 69 which will be described hereinafter).

[0230] (Mounting of Jaw Seal)

[0231] After mounting various seals described in the foregoing, the jaw seal 42 is stuck on the seat surface 12b5. As shown in FIGS. 42 and 43, the jaw seal 42 is stuck. The opposite longitudinal ends of the jaw seal 42 ride on the associated end seals 34 and are bonded thereto by adhesive material. As shown in FIG. 45, the free end, extending in the longitudinal direction of the process cartridge, of the jaw seal 42 is pressed against the developing roller codirectionally with respect to the peripheral movement of the surface of the developing roller. (In this embodiment, the new cartridge is not provided with the jaw seal, since the toner in the developer container is confined therein by the seal 31.)

[0232] (Side Cover Seal)

[0233] A side cover seal is provided for the purpose of back-up and toner leakage prevention at a portion where the bent portion of the jaw groove filling seal 68 and end portions of the jaw seal 42 are overlapped with the end lateral seal 66.

[0234] As shown in FIG. 44, such a surface of the arcuate portion 12a6 of the developing device frame 12aas does not face the developing roller 10d,there is provided with a rib 12a36. The lower developing frame 12bis provided with a rib 12b6, which is parallel with the rib 12a36 with the longitudinal gap g between the lower developing frame 12band the arcuate portion 12a6 of the developing device frame 12adisposed between the ribs. The side cover seal 69 has a width that is equal to the gap between the ribs 12a36 and 12b6. The side cover seal 69 is stuck and extended from a position C at a free end (in the direction of a width, that is, perpendicular to the longitudinal direction) of the flange 12a16 (FIGS. 4 and 8) of the developing device frame 12a, is then folded back over the free end portion D to embrace the groove filling seal 68 and the jaw seal 42 end as shown in FIG. 45. By doing so, the jaw seal 42 at a longitudinal extension of the jaw seal sticking seat surface 12b5 of the lower developing frame 12bis closely contacted to the jaw groove filling seal 68, and the jaw seal 42 is not easily removed from the sticking seat surface 12b5 at an edge of a side surface of the seal 68.

[0235] (Mounting of Developing Blade)

[0236] When a developing device frame 12ais deformed, for example, a gap is produced between the metal blade 10e2 and the seal 35. Here, the seal 35 is long, and therefore, the sealing property is relatively not very good. In view of this, a re-assembling of this embodiment will be described according to which the performance of the toner developing container 12 is substantially the same as a new one.

[0237] A seal is provided in addition to the seal 35 in consideration of the case that the sealing property of the seal 35 of the toner developing container 12 is deteriorated.

[0238] The developing blade 10ehaving been removed is subjected to simultaneous air suction and air blowing, or the like such that deposited toner is removed from the blade to clean it.

[0239] Then, the developing blade 10eis inspected to determine whether it is reusable or not. If the result of the inspection indicates that performance thereof is lower than a predetermined standard, it is replaced with a new one.

[0240] Between the blade mounting seat surfaces 12a4 at the opposite ends of the developing device frame 12a, a flange is provided, which is provided with a mounting seat 12a3.

[0241] The bent portion of the metal blade 10e2 of the developing blade 10eshown in FIG. 16 is urged toward the seat 12a3 of the flange of the developing device frame 12awith the seal 35 compressed therebetween, and the holes 10e7 of the metal blade 10e2 are fitted around the positioning dowels 12a11 provided on the developing blade mounting seat surface 12a4. Then, a small screw 10e4 (only one longitudinal end portion of the metal blade 10e2 is shown) is threaded into the developing blade mounting seat surface 12a4 through the hole 10e7 provided adjacent each of the opposite longitudinal ends of the metal blade 10e2 so that the developing blade 10eis fixed to the developing device frame 12a.

[0242] This is the end of the developing blade mounting step to mount the developing blade on the separated toner developing container 12.

[0243] (Developing Roller Mounting Step)

[0244] The developing roller 10d,which has been removed, is subjected to the air suction and simultaneous air blowing or another process to clean it by removing the deposited toner.

[0245] Then, the developing roller 10dis inspected, and it is determined whether or not it is reusable. If the determination is negative, that is, the performance does not satisfy a predetermined reference, the developing roller is replaced with a new one.

[0246] The developing roller 10dmay be worn due to the friction with the developing blade 10e.Therefore, when the statistical probability that replacement is necessary on the basis of the inspections during development thereof or remanufacturing thereof, the developing roller may be replaced with a new one without the inspection, and by doing so, the remanufacturing operation is efficient.

[0247] In the inspection of the developing roller 10d, it is disassembled into the main body of the developing roller, the magnet 10c,the bearings 33a,33b,the spacer rollers 10d1, the roller electrode (unshown), the developing roller gear 10f,and so on, which are inspected, respectively, to find reusable parts. The non-reusable parts are replaced with new ones.

[0248] As for the gear train 61 for driving the toner feeding member 10brotatablely supported on the developing device frame 12aand the lower developing frame 12b, the development holder 37 is removed, and the gear train is cleaned and inspected, and is replaced with an usable parts, and they are reassembled prior to the assembling of the used or new developing roller 10d.

[0249] Referring to FIGS. 15 and 16, the process of mounting the developing roller 10dto the toner developing container 12 will be described.

[0250] The development holder 37 is engaged with the developing device frame 12a. A small screw 57 is threaded into the developing device frame 12athrough the development holder 37 so that development holder 37 is fixed to the developing device frame 12a. Then, a journal hole at an end of the developing roller 10dis engaged with a bearing 33bof the development holder 37. Subsequently, at a longitudinal end which is opposite from the bearing 33b,the bearing 33ais engaged in the journal at the other end of the developing roller 10d, and the bearing 33ais aligned with the developing device frame 12a. Into a D-shaped shaft portion provided at the journal end of the developing roller 10dprojected outwardly beyond the bearing 33a,the developing roller gear 10f,having a hole which has the complementary shape and size, is fitted. Then, the engaging portion 36aof the development holder 36 is engaged with a cylindrical engaging portion 33a3 of the bearing 33a.At this time, one end of the magnet 10cis engaged with a D-shaped hole 36d,which is provided longitudinally outwardly beyond the bearing hole. The shaft portion at the end of the magnet 10chas a complementary shape and size with the D-shaped hole 36d.Then, a small screw 56 is threaded into a female screw 12a13 of the developing device frame 12athrough the hole 36cof the development holder 36 and the hole 33a1 of the bearing 33a.By doing so, the development holders 37, 36 are fixed to the developing device frame 12a, and the developing roller 10dis supported by the toner developing container.

[0251] This is the end of the process of mounting the developing roller 10dto the separated toner developing container 12.

[0252] The toner developing container 12 to which the developing roller 10dis mounted is shown in FIG. 11. A new toner developing container 12 and a remanufactured toner developing container 12 are the same as seen in FIG. 11.

[0253] (Developing Blade Top Seal)

[0254] If the toner developing container 12, particularly, the surface on which the seal 35 is stuck, is deformed during transportation, a gap is formed between the metal blade 10e2 and the seal 35. So, there is a liability that toner leaks between the longitudinal end edge of the metal blade 10e2 and the developing device frame 12a.

[0255] In view of this, as shown in FIG. 46, a seal is stuck on the outside of the toner developing device frame 12aover the metal blade 10e2 and the cap member 12c. The seal is called here a blade top seal 49. As shown in FIG. 29, a scraper 60 is fixed to the metal blade 10e2. The free end 60aof the scraper 60 is contacted to the developing roller 10dby its elastic force. The free end 60ais inclined relative to the generating line of the developing roller 10d.

[0256] The inclining direction of the free end 60ais in the downstream direction with respect to the peripheral movement of the developing roller 10dtoward the longitudinally inside. By doing so, the toner deposited on the developing roller 10dis prevented from moving in the longitudinally outward direction, so that toner returns from the end of the jaw seal 42 into between the jaw seal 42 and the developing roller 10d.

[0257] A longitudinal end of the blade top seal 49 stuck on the metal blade 10e2 and the cap member 12csuch that it closes the gap between the metal blade 10e2 and the cap member 12cin the longitudinal direction, is within a range where the scraper 60 exists.

[0258] By doing so, the seal sticking step for sticking the seal for preventing the toner from leaking, over the metal blade portion of the developing blade 10eand the toner developing container 12, is completed.

[0259] The seal sticking step may be carried out immediately after the developing blade 10eis mounted to the toner developing container 12.

[0260] The blade top seal 49 is an adhesive tape.

[0261] (Toner Filling Step)

[0262] Toner is filled into the toner developing device frame 12awhich has been sealed at various positions described above, through the toner filling opening 12a2, and a toner cap 32 or plug is press-fitted into the toner filling opening 12a2 to seal it.

[0263] In an alternative of the method, the toner may be filled before the developing blade 10eand the developing roller 10dare remounted. In such a case, as shown in FIG. 56, the toner developing container 12 is placed with the toner supply opening 12a1 face up and the toner accommodating portion 10aat a lower position. A free end of a funnel 47 is inserted into the opening 12a1, and the toner is let fall from the toner bottle 48 onto the funnel 47. After the toner filling, the developing blade 10eand the developing roller 10dare remounted in the same manner as with the case described above. A metering supplying device, provided with an auger, may preferably be provided in the funnel, since then the toner can be efficiencyly supplied.

[0264] Thus, the toner filling step of filling toner into the toner accommodating portion 10athrough the toner supply opening 12a1 is completed.

[0265] The toner does not leak out through the gap g in the form of a crank at the end portions of the developing device frame 12aand the lower developing frame 12bbecause of the sealing material 64 provided as described hereinbefore.

[0266] The toner end lateral seal 66 is effective to prevent the leakage that may otherwise occur between the jaw seal (blow-out preventing seal) 42 and the end seal 34.

[0267] In addition to the end lateral seal 66, the jaw groove filling seal 68 is effective to seal the end of the end seal 34, and further, the side cover seal 69 is effective to back up the sealing function of the jaw seal 42 and the end seal 34, so that toner leakage is further prevented.

[0268] Moreover, a side pad 65 stuck on the elastic blade 10e1 of the developing blade 10econtacts the corner formed between the seal 35 and the end seal 34, and therefore, the longitudinal end of the elastic blade 10e1 is closely contacted to the developing roller 10d,and is sealed by the side pad 65, and the toner is prevented from leaking out of the longitudinal ends of the elastic blade 10e.

[0269] Therefore, no toner is leaked out of the inside of the toner developing container 12 having the developing roller 10dand the developing blade 10eduring normal transportation and handling.

[0270] (Coupling of Toner Developing Container and Cleaner Container)

[0271] The coupling step for the toner developing container 12 and the cleaner container 13 is similar to the coupling for the toner developing container 12 and the cleaner container 13 having the toner seal. Therefore, the description thereof will be made in conjunction with FIGS. 11, 7 and 26.

[0272] In FIG. 11, the arm portions 38 of the toner developing container 12 are inserted into the recesses 13hof the cleaner container 13. As shown in FIG. 26, the through hole 38band the elongated bore 38b1 of the arm portion 38 are aligned with the holes 13con the outer wall surface 13qof the cleaner container 13. When the hole 13cand the through hole 38band the elongated bore 38b1 are aligned, the through hole 38band the elongated bore 38b1 are aligned with the holes 13ein the surface 13dof the inner wall of the cleaner container 13. Then, the pin 41 is inserted through the holes 13cof the cleaner container 13 and the hole 38band the elongated bore 38b1 of the arm portion 38 of the toner developing container 12. Further, the pin 41 is press-fitted into the hole 13ein the inner wall of the cleaner container 13. As shown in FIG. 7, the end portions of the tension coil spring 59 are hooked on the spring hook 12a29 of the toner developing container 12 and the spring hook 13pof the cleaner container 13, thus stretching the tension coil spring 59. By this, the photosensitive drum 7 is press-contacted to the spacer rollers 10d1 at the end portions of the developing roller 10d.

[0273] In this manner, the remanufacturing of the process cartridge is possible without remounting of the toner seal 31.

[0274] (Remanufacturing of Cleaner Container)

[0275] During the remanufacturing of the toner developing container 12, the separated cleaner container 13 is remanufactured.

[0276] FIG. 11 is a perspective view showing the cleaner container 13 having the photosensitive drum 7, the charging roller 8, and the cleaning blade 11a.FIG. 47 is a longitudinal sectional view wherein the photosensitive drum 7 is mounted to the cleaner container 13. FIG. 48 shows a structure for supporting the charging roller 8 on the cleaner container 13.

[0277] As shown in FIG. 47, the photosensitive drum 7 is provided at one end of the drum cylinder 7a(hollow aluminum cylinder) having a photosensitive layer thereon with a flange 51 and is provided at the other end with a flange 52. The flanges are fixed to the drum by bonding or crimping. The flange 51 is provided with a drum gear 51a. The flange 52 has a transfer roller driving gear 52a. The drum shafts 53a,53bpenetrating the flanges 51, 52, are received by holes 13k, 13mof the cleaner container 13 and are supported by the cleaner container 13. When the process cartridge B is mounted to the main assembly 14 of the image forming apparatus, the drum gear 51ais brought into meshing engagement with the driving gear 22 of the main assembly 14 of the image forming apparatus shown in FIG. 2, and the transfer roller driving gear 52ais brought into meshing engagement with the unshown gear fixed to the transfer roller 4. When the coupling between the cleaner container 13 and the toner developing container 12 is completed, the drum gear 51ais engaged with the developing roller gear 10fof the developing roller 10d.

[0278] As shown in FIG. 48, the charging roller 8 comprises a metal shaft 8aand a rubber roller thereon having an intermediate resistance, and the metal shaft 8ais exposed at the end portions.

[0279] As shown in FIG. 48, the shaft 8aof the charging roller 8 is rotatably engaged in charging roller bearings 8c,which are slidably engaged in the guide groove 13gextended substantially on a line connecting the centers of the photosensitive drum 7 and the charging roller 8. The charging roller bearing 8cis urged toward the photosensitive drum 7 by the compression coil spring portion 8b, which is compressed between the charging roller bearing 8cand the spring seat 13sat one end of the guide groove 13g, so that the charging roller 8 is press-contacted to the photosensitive drum 7. The charging roller 8 is driven by the photosensitive drum 7. The compression coil spring 8bis held in the bearing 8c.

[0280] An unshown electrode is contacted to the metal shaft 8aof the charging roller 8, and is extended to an outside of the process cartridge B. The outer contact portion of the electrode is electrically connected with a contact portion of the main assembly 14 of the image forming apparatus, which is connected with an outer contact portion in the main assembly.

[0281] The cleaning blade 11a,as shown in FIG. 4, comprises a metal blade 11a2 and an elastic blade 11a1 of rubber or the like fixed to the metal blade 11a2 and contacted to the photosensitive drum 7 along a generating line thereof. As shown in FIG. 4, the cleaning blade 11ais fixed to the cleaner container 13 by threading a small screw 11a4 through a hole at the end portions of the metal blade 11a2.

[0282] A description will be provided as to dismounting of the photosensitive drum 7, the charging roller 8 and the photosensitive drum 7 from the cleaner container 13.

[0283] The photosensitive drum 7 is dismounted from the cleaner container 13 when the shafts 53a,53bare pulled out of the center holes of the flanges 51, 52, shown in FIG. 47.

[0284] When the photosensitive drum 7 is dismounted, the charging roller 8 is moved in a direction perpendicular to axis, so that bearings 8care moved along the guide groove 13g, by which the bearing 8cif dismounted from the guide groove 13gtogether with the charging roller 8. The bearing 8cis disengaged from the shaft 8a, and the compression coil spring 8bis dismounted. In this manner, an opening G between the cleaning blade 11aand the receptor sheet 11band extending in the longitudinal direction appears (FIG. 4).

[0285] The removed photosensitive drum 7, the charging roller 8cand the bearings 8c, are subjected to inspections to determine whether they are to be reused or not, and if they should be reused, it is assembled into the cleaner container 13 in the reassembling operation, which will be described hereinafter, and if not, a new part or parts are used. Usually, however, the photosensitive drum 7 has such a long lifetime that it is still usable at the time when the toner is used up.

[0286] (Removal of Residual Toner in Cleaner Container)

[0287] The residual toner in the cleaner container 13 is removed after the photosensitive drum 7, the charging roller 8, the bearing 8cand the like are removed.

[0288] Referring to FIGS. 49, 50 and 51, a description will be provided as to the removal of the toner contained in the removed toner accommodating portion 11cof the cleaner container 13.

[0289] FIG. 49 shows a cleaning device for the cleaner container. The cleaner container 13 is set in a casing 70aof the cleaning device 70. The casing 70aseals the inside against the atmosphere. The cleaner container 13 is impacted by an impacting device 77, which is carried on the pivoting device 73, and the residual toner is sucked out of the set by a suction device 79. Simultaneously, the cleaner container 13 is swung about a shaft 76bby a swing device 73.

[0290] FIG. 50 shows details of an air block 79aof the suction device 79. The air block 79ais generally hollow, and has a close contact surface 79gto be contacted to the edge of the opening G of the cleaner container 13, the close contact surface 79gbeing coated with a rubber-like seal member 79bexcept for the ejection opening 79dand the suction opening 79e.An air supply tube 79cfor supplying the air into the cleaner container 13 is disposed in the air block 79a, and an air blow opening 79dopens adjacent a longitudinal end of the above-described close contact surface 79g. Furthermore, a suction tube 79fis disposed in the air block 79a, and the suction opening 79eof the suction tube 79fis disposed adjacent the other end of the close contact surface 79g. The close contact surface 79ghaving the air blow opening 79dand the suction opening 79eis contacted to the cleaning blade 11aand the receptor sheet 11bof the cleaner container 13, which has been moved in the direction of arrow K3 to a cleaning position M2 by a table 72, so that in the opening G between the edges of them is completely covered. This is indicated by chain lines in the opening G in FIG. 50, and more particularly, the sealing range A1, the air blowing opening A2 and the air discharging outlet A3. The sealing range A1, the air blowing opening A2 and the air discharging outlet A3 corresponds to the close contact surface 79g, the air blow opening 79dand the suction opening 79e, respectively. In the suction device 79, compressed air Q1 is supplied into the cleaner container 13 closely contacted to the air block 79afrom the air supply tube 79cthrough the air blow opening 79dclosely contacted to the air blowing opening A2 and through the opening G (arrow Q2) to scattered the residual toner; and the residual toner and the air are sucked from the cleaner containered 13 through the suction opening 79eclosely contacted to the air discharging outlet A3 (arrow Q3) into the suction tube 79f(arrow Q4).

[0291] The residual toner leaked out of the air block 79aand cleaner container 13, is sucked by an auxiliary suction device (unshown) with the atmosphere in the suction device 75 through the ambience suction opening 78, as shown in FIG. 49.

[0292] Referring to FIGS. 49 and 50 and the flow chart of FIG. 51, a description will be provided as to the cleaning method of the cleaner container 13 and the operation of the cleaning device 70 in detail.

[0293] The operation of the cleaning device (cleaner) 70 is started at step (S1). Then, the cleaner container 13 to be cleaned is placed on the top of a table 72, which is at a home position at this time (S2). The cover 70bis closed (S3), which event is detected by a sensor (door switch) 70d(S4), and an air cylinder of a clamping device (unshown) is actuated (S5), by which the top side of the cleaner container 13 is pushed.

[0294] By this, the cleaner container 13 is clamped on the table 72 at a predetermined position. An air cylinder 75 having a piston rod directly connected to the table 72 is actuated (S7), so that table 72 moves from the home position M1 on the slide base 71 to a cleaning position M2 in the swing device 73 (S8), and the opening G of the cleaner container 13 is closely contacted to the surface 79gof the suction device 79.

[0295] Then, a motor 77ais actuated (S9), and the impacting device 77 is started, by which the pin 77bof the crank to which the shaft of the motor 77ais fixed is swung about a pin 77dsupporting the yoke 77c. Impact is applied to a point P (FIG. 50) on the top aide of the cleaner container 13 by a hummer 77gfixed to an end of the leaf spring arm 77efixed to the yoke 77c(S10). By doing so, the residual toner deposited on the inner wall of the cleaner container 13 is forced to fall, and the mobility of the residual toner is enhanced. A rotary actuator 76 is started (S11), and the swing table 73aof the swing device 73 reciprocates about a shaft 76bswingably supporting the swing table 73awithin the range of α=0-80° (S12). The swing table 73ais stopped by abutting stoppers 71a, 71b, the positions of which are adjustable. A stop valve (unshown) for the compressed air is opened (S13, S14) to supply the compressed air into the cleaner container 13 through the air blow opening 79d(FIG. 50) and the opening G, and simultaneously, the air in the cleaner container 13 is sucked through the opening G and the suction opening 79etogether with the residual toner. The operation is continued for a proper period.

[0296] The swing table 73ais swung through one reciprocation (S15). A rotary actuator 76 is deactivated (S16), and the horizontal position N1 of the swing table 73ais checked (S17), and then, the motor 77ais deactivated (S18, S19), so that impact imparted by the hammer to the position N1 ends. The stop valve is closed (S20, S21). The air cylinder 75 is urged in the resetting direction (S22), and then, the table 72 located at the cleaning position M2 is returned to the home position M1 and the device determines whether it is returned to the home position (S23). In response this, an unshown clamping air cylinder is deactivated (S24), and the clamp of the cleaner container 13 relative to the table 72 is released (S25). Then, the cover 70bis opened (S26), and the cleaner container 13 is taken out of the casing 70a(S27). The device them determines whether cleaning of the next cleaner container is to occur (S28). If cleaning of the next cleaner container is to occur, the method returns to step (S2). If not, the method proceeds to step (S29). This is the end of the cleaning operation for the cleaner container 13.

[0297] In the cleaning step, the impact to the cleaner container 13 by the device 77 continues in the period between the steps S9 and S18 in the flow chart of FIG. 51, and contemporaneously therewith, the swing action of the cleaner container 13 and the suction of the residual toner are carried out. Thus, the residual toner deposited on the inner wall or the like of the cleaner container 13 are beaten out, and the residual toner is smoothly moved toward the opening G. The compressed air blown out from the air blow opening 79dis effective to scatter around in the cleaner container 13, and the residual toner is sucked from the suction opening 79e. By the series of the operations, the residual toner can be substantially completely removed from the cleaner container 13.

[0298] After the cleaning, the cleaning blade 11ais removed from the cleaner container 13 by unthreading the small screw 11a4 (FIG. 4). Then, the receptor sheet 11bis removed from the cleaner container 13. Then, while sucking the air from the inside of the cleaner container 13, compressed air is blown into the cleaner container 13, thus cleaning the inside of the cleaner container 13. Thereafter, a new receptor sheet 11bis stuck on the cleaner container 13. Holes 11a3 of a new cleaning blade 11aat the end portions (FIG. 11 shows only one end portion) are brought into engagement with the positioning projections 13iof the cleaner container 13, and small screw 11a4 is threaded into the cleaner container 13 through the hole of the metal blade 11a2.

[0299] Then, a charging roller 8 engaged with the bearings 8cto which the compression coil springs 8bare mounted, is mounted on the shaft 8a. This is done by engaging the bearing 8cinto the guide groove 13gwith the compression coil spring 8bat the leading side. Thereafter, as shown in FIG. 47, the photosensitive drum 7 is engaged between the end walls of the cleaner container 13, and the center holes 51b, 52bof the flanges 51, 52 are aligned with holes 13k, 13min the end walls at the opposite ends of the cleaner container 13, and then, the drum shafts 53a,53bare engaged into the holes 13k, 51b, 52b, 13m. The drum shafts 53a,53bare press-fitted in the holes 13m, 13k, and the drum shafts 53a,53bare slidably engaged in the holes 51b, 52b. The photosensitive drum 7 in the unit is rotatable on the drum shafts 53a,53b.

[0300] (Gap between Photosensitive Drum and Developing Roller)

[0301] When the photosensitive drum 7 and the developing roller 10dcontact each other, the drum gear 51aand the developing roller gear 10fare in meshing engagement with each other. When the process cartridge is transported with the drum gear 51aand the developing roller gear 10fin meshing engagement with each other, the tooth surfaces of the gears are in contact, and therefore, they may be rotated by impact or vibration. If the direction of the rotation is as indicated by an arrow AAA in FIG. 52 (the same direction as in the image forming operation), there is no problem. However, the direction of the rotation is not assured, since the vibration or the impact during transportation occurs at random. If the photosensitive drum 7 rotates in the direction indicated by an arrow BBB, that is, if the photosensitive drum 7 and the developing roller 10dare rotated in the direction opposite from the normal direction, the toner may leak out through between the jaw seal 42 (blow-out preventing sheet) and the developing roller 10d, and in the worst-case, the seal 42 may be wound around the developing roller since the preventing sheet contacts the developing roller counter-directionally. In addition, the scraper 60 mounted to each of the opposite ends of the developing blade 10eand functioning to guide the toner inwardly at the opposite ends of the developing roller 10dcan operate correctly when the developing roller 10drotates in the normal direction, and therefore, if it is rotated in the wrong direction, the toner may leak out at the opposite ends of the developing roller 10d.

[0302] In this embodiment, the back clearance of the meshing between the drum gear 51aand the developing roller gear 10fis made larger than that during the image formation operation to avoid abutment between the tooth surfaces during transportation. Another alternative is to disengage them for transportation.

[0303] Referring to FIG. 54, a description will be provided as to the means for maintaining the disengaged state or large back clearance between the drum gear 51aand the developing roller gear 10f.In the case of FIG. 53, a tape 81 is stuck over the toner developing container 12 and the cleaner container 13 with the drum gear 51 a and the developing roller gear 10fdisengaged from each other or with the large back clearance.

[0304] More particularly, a force is applied to bias the toner developing container 12 and the cleaner container 13 toward each other at positions across a vertical surface passing through a point P which is a pivot between the toner developing container 12 and the cleaner container 13 from the portion where the photosensitive drum 7 and the developing roller 10dare provided, as indicated by an arrow N in FIG. 53, by which the back clearance between the drum gear 51aand the developing roller gear 10fis increased, or they are disengaged from each other. The force is opposed by the spring force provided by the tension coil spring 59 (FIG. 7) and the compression coil spring 40 (FIG. 11) for urging the photosensitive drum 7 and the developing roller 10dtoward each other. Therefore, the tape 81 is stretched by the springs 40, 59. Therefore, the tape 81 has sufficient width and thickness such that stress during transportation is within a tolerable range, and in addition, the adhesive material or the adhesive material for the tape has also sufficient bonding strength against the toner developing device frame 12aand the cleaner container 13.

[0305] (Embodiment 2)

[0306] A description will be provided as to Embodiment 2 in conjunction with the accompanying drawings.

[0307] A description will be provided as to general arrangements of the image forming apparatus and a process cartridge according to an embodiment of the present invention, and then as to an assembling method of the process cartridge. The process steps of disassembling and reassembling the process cartridge and the reassembled process cartridge will be described finally.

[0308] Referring to FIGS. 57 to 61, the process cartridge and the image forming apparatus to which the process cartridge is detachably mountable, will be described.

[0309] (General Arrangement)

[0310] The image forming apparatus in this embodiment is an electrophotographic image forming apparatus (laser beam printer) A, as shown in FIG. 57, wherein an electrophotographic photosensitive member in the form of a drum is exposed to information light modulated in accordance with image information from an optical system 1, so that a latent image is formed on the photosensitive member, and the latent image is developed into a toner image. In synchronism with the formation of the toner image, the recording material 2 is fed out, one by one, from a sheet feeding cassette 3ausing a pick-up roller 3band separation claws 3cpress-contacted at the corners of the top surface of the recording material 2, and the sheet is fed by feeding means 3 including a feeding path 3dand a pair of registration rollers. The toner image formed on the electrophotographic photosensitive member in the process cartridge B is transferred onto the recording material 2 by applying a voltage to transfer means in the form of a transfer roller 4, and then the recording material 2 is fed to fixing means 5 on a feeding path 3f.The fixing means 5 comprises a driving roller 5aand a fixing roller 5ccontaining a heater 5btherein, and pressure and heat are imparted to the recording material 2, which is passing therethrough, by which the transferred toner image is fixed on the recording material. The recording material 2 is further fed by discharging rollers, and is discharged to a discharging portion 6 through a reverse feeding path.

[0311] On the other hand, the process cartridge B contains the electrophotographic photosensitive member and at least one of process means. Here, the process means includes charging means for electrically charging the electrophotographic photosensitive member, the developing means for developing a latent image formed on the electrophotographic photosensitive member, and cleaning means for cleaning the surface of the electrophotographic photosensitive member to remove residual toner. As shown in FIG. 60, in the process cartridge B of this embodiment, the electrophotographic photosensitive member in the form of an electrophotographic photosensitive drum 7 having a photosensitive layer is rotated, and a voltage is applied on the charging roller 8, which is the charging means, so that the surface of the photosensitive drum 7 is uniformly charged, and the photosensitive drum 7 is exposed to a light image from the optical system 1 through an opening 9, by which an electrostatic latent image is formed, and the image is developed by developing means 10.

[0312] In the developing means 10, the toner in a toner accommodating portion 10ais fed out by feeding means in the form of a rotatable toner feeding member 10b,and a developing roller 10dcontaining therein a stationary magnet is rotated, by which a layer of toner particles triboelectrically charged by the developing blade 10eis formed on the surface of the developing roller 10d. The toner is selectively transferred onto the photosensitive drum 7 so that toner image is formed. The developing roller 10dfunctions to supply the toner to the photosensitive drum 7. The developing blade 10efunctions to regulate the thickness of the toner layer on the surface of the developing roller 10d.

[0313] The transfer roller 4 is supplied with a voltage having a polarity opposite from the polarity of the toner image, by which the toner image is transferred onto the recording material 2. Thereafter, the residual toner remaining on the photosensitive drum 7 is scraped off by the cleaning blade 11a,and the removed toner is received by a receptor sheet 11b,and the received toner is collected into a removed toner accommodating portion 11c.

[0314] (Cartridge Mounting Means)

[0315] Various parts, such as the photosensitive drum 7, are supported and accommodated in a cartridge frame, which is provided by coupling the toner developing container 12 and the cleaner container 13. The cartridge is mounted to the main assembly 14 of the apparatus.

[0316] In the cartridge mounting means, when the cover member 15 is opened by rotating it about the shaft 15a(FIGS. 57, 58), there are guide grooves 16, which are inclined toward the rear side at each of the left and right sides of the cartridge mounting space as shown in FIG. 58. The guide grooves 16 are disposed substantially symmetrically. The guide grooves 16 are substantially linear. At the inlet side of the guide grooves 16 there are provided a positioning portion 16c(main assembly side positioning portion 16c).

[0317] On the other hand, at the opposite outer ends of the process cartridge, there are provided guide portions corresponding to the guide grooves 16 to be guided by the guide grooves 16. The guide portions are projected substantially symmetrically at the opposite longitudinal ends, respectively. As shown in FIG. 61, it comprises a boss 18 and a rib 19, which are integral. The boss 18 and the rib 19 are integrally formed with the cleaner container 13 to which the photosensitive drum 7 is mounted, and the boss 18 is disposed on an extension of a rotational axis of the photosensitive drum 7, and the rib 19 is extended from the boss 18 in an inserting direction of the process cartridge B as indicated by an arrow C in FIG. 61. The rib 19 extends inclined downwardly in conformity with the guide grooves 16.

[0318] With this structure, when the process cartridge is to be mounted to the main assembly, as shown in FIG. 58, the cover member 15 is open, and the ribs 19 are engaged into the guide grooves 16, and then, the process cartridge B is inserted into the main assembly 14 of the apparatus. When the process cartridge B is further inserted, the boss 18 of the process cartridge B is seated on the main assembly side positioning portion 16cin the inlet of the guide groove 16. Simultaneously, the free end 19aof the rib 19 abuts a stopper surface 16aof the guide grooves 16 by a moment about the boss 18 produced by the weight of the process cartridge B. Thus, the drum gear 51a(FIG. 61) fixed to an end of the photosensitive drum 7 is brought into meshing engagement with a driving gear 22 (FIG. 58) provided in the main assembly 14, so that a driving force can be transmitted to the process cartridge B.

[0319] Then, the cover member 15 is closed, by which the shutter opening lever 55, which is interrelated with the cover member, is rotated in the clockwise direction about the shaft 55cfrom a position 55ato a position 55b, so that it is engaged with a pin 28aprovided on the drum shutter member 28 as shown in FIG. 10, and the drum shutter member 28 is opened about a pin 29 mounted to the cleaner container 13 against a spring force of a spring 27, thus opening a transfer opening 13n. The coil spring 27 is fitted around the pin 29, and one end thereof is engaged to the cleaner container 13, and the other end is engaged to the drum shutter member 28, and therefore, when the cover member 15 is open or when the process cartridge B is outside the main assembly 14, the drum shutter member 28 closes the transfer opening 13nby the spring force.

[0320] When the process cartridge B is to be taken out, the cover member 15 is opened, and the shutter opening lever 55 is rotated about the shaft 55cto return from the position 55bto the position 55a. Then, drum shutter member 28 rotates about the pin 29 by the spring force of the coil spring 27, thus closing the transfer opening 13n. The process cartridge B is pulled up such that the boss 18 is away from the positioning portion 16c, and thereafter, the process cartridge B is further pulled up such that ribs 19 are guided by the guide grooves 16.

[0321] (Structure of Cartridge Frame)

[0322] A description will be provided as to the structure of the cartridge frame. The cartridge frame is made of polystyrol resin material by injection molding, and as shown in FIG. 60, a lower developing frame 12bis welded to a side of the developing device frame 12a, and a cap member 12cis welded to the upper portion, thus constituting a toner developing container 12. A cap member 13bis welded to a top of a cleaning frame 13ato constitute an integral cleaner container 13. Then, the cleaner container 13 is coupled with the toner developing container 12 to constitute a cartridge frame.

[0323] The developing device frame 12ais provided at an end thereof with a toner supply opening 12a1, as shown in FIGS. 69, 70, and is also provided at one longitudinal end with a toner filling opening 12a2. The developing device frame 12ais provided therein with a plurality of erected supporting members (not shown) in the longitudinal direction. The toner supply opening 12a1 permits the supply of the toner from the toner accommodating portion 10ato the developing roller 10d. The toner in the toner accommodating portion 10ais supplied to the developing roller 10dthrough the toner supply opening 12a1.

[0324] When the developing means is mounted in place, as shown in FIGS. 60 and 69, a toner feeding member 10bis mounted in the developing device frame 12a, and thereafter, the cap member 12cis welded to the developing device frame 12a. Subsequently, a toner seal 31 in the form of a film is welded on a surface 12a5 of the seat formed around the circumference of the toner supply opening 12a1 of the toner developing container 12 to seal the opening 12a1. Then, the toner is filled through the toner filling opening 12a2, and thereafter, the filling opening 12a2 is plugged by a cap 32 to seal the toner accommodating portion 10a. The toner seal 31 sealing the toner supply opening 12a1, as shown in FIG. 69, is folded back at one longitudinal end of the opening 12a1, and the free end thereof is extended out through a slit 12a8 of the developing device frame 12a. The free end of the toner seal 31 is nipped by fingers of the user and is pulled out when the user starts the use of the process cartridge B.

[0325] When it is pulled out, the sealing is not complete at the portion where the toner seal 31 extends through the toner developing container 12.

[0326] Therefore, as shown in FIG. 69, an elastic sealing material 10h, such a felt, is provided in the slit 12a8 at an end, closer to the free end, of the toner seal 31.

[0327] As shown in FIG. 69, the elastic sealing material 10his overlaid on the toner seal 31 and biases the toner seal 31. Therefore, when the toner seal 31 is pulled out, the elastic sealing material 10hoccupies the slit 12a8, which has been occupied by the toner seal 31 to be press-contacted to a wall of the developing device frame 12a, thus preventing leakage of the toner to the outside.

[0328] A description will be provided as to the mounting of the elastic sealing material 10h. As shown in FIG. 71, a part of the arcuate portion 12a6 of the developing device frame 12ais provided with an angle groove 12a26 extending in the longitudinal direction. The bottom of the angle groove 12a26 is flush with the toner seal sticking seat surface 12a5. An elastic sealing material 10h, such as a felt or the like, is stuck on a piece 10jengaged in the angle groove 12a26.

[0329] With this structure, even when the toner seal 31 is pulled out, the toner is prevented from leaking to the outside of the toner developing container 12 through the slit 12a8.

[0330] Then, the lower developing frame 12bis welded to the developing device frame 12a. As shown in FIG. 64, the developing device frame 12ais provided at the opposite longitudinal ends of the toner supply opening 12a1 with arcuate portions 12a6 at which the end seals 34 are to be mounted. A flat flange 12a16 is extended between the arcuate portions 12a6 below the seal sticking seat surface 12a5, and the flange 12a16 is substantially perpendicular to the seal sticking seat surface 12a5. On the other hand, the lower developing frame 12bis engaged with the developing device frame 12ain the longitudinally opposing surfaces of the arcuate portions 12a6. Therefore, in consideration of manufacturing errors, the lower developing frame 12bhas a length which is smaller than the distance between the opposing surfaces of the arcuate portion 12a6 by 2×g, where g is a gap at each end. The flange 12a16 is provided with holes 12a17, and the lower developing frame 12bis provided with dowels 12b3 for engagement with the holes 12a17, respectively. With the dowels 12b3 being in engagement with the respective holes 12a17, the bottom surface of the lower developing frame 12band the top surface of the flange 12a16 of the developing device frame 12aare welded to each other. By doing so, gap g is formed between the arcuate portion 12a6 and the lower developing frame 12bat each end. The dimension of the gap g is not constant when the lower developing frame 12bis fixed to the developing device frame 12a.

[0331] Each of the opposite ends of the lower developing frame 12bis provided with an outward projection 12b2 (FIGS. 50 and 64). The developing device frame 12ais provided at each of the end portions with a recess 12a18 for engagement with a projection 12b2 when the dowels 12b3 are engaged with the holes 12a17 for the purpose of welding or bonding of the lower developing frame 12b. As shown in FIGS. 74, 75, 76 and 65, a gap g1 is provided between the recess 12a18 and the projection 12b2. The gap is substantially equal to the gap g formed between the lower developing frame 12band the arcuate portion 12a6.

[0332] As shown in FIG. 65, the gap between the projection 12b2 and the recess 12a18 is sealed by sealing material 39.

[0333] As shown in FIG. 64, the arcuate portion 12a6 of the developing device frame 12ais provided with a sticking portion 12a20 to which the end seal 34 is stuck. The sticking portion 12a20 has an arcuate peripheral surface having a common axis with the arcuate portion 12a21 provided longitudinally outside of the arcuate portion 12a6. The axis is the rotational axis of the developing roller 10din the toner developing container 12. The sticking portion 12a20 is provided with an arcuate surface having a radius which is smaller than that of the outer arcuate portion 12a21. An end of the sticking portion 12a20, as shown in FIG. 8, ends short of (inside) the circumference of the outer arcuate portion 12a21.

[0334] As shown in FIGS. 73, 74, and 75, when the lower developing frame is welded to or bonded to the developing device frame 12a, a slit 12dis provided between the arcuate portion 12a6 and the lower developing frame 12b.

[0335] The slit 12d, as shown in FIGS. 77 to 79, is on an optical path of a laser beam passing through a gap (development gap) formed between the photosensitive drum 7 and the developing roller 10dprovided by the spacer roller 10d1 which is disposed to each of the opposite and portions of the photosensitive drum 7 and the developing roller 10d. Optical path passes through the slit 12d, a slit 10e6 provided in the metal blade 10e2 and a hole 13b1 formed in the cap member 13b.

[0336] In FIGS. 77-79, the laser beam emitted from the laser source 86 has a width which is larger than the gap (approximately 300 μm) between the photosensitive drum 7 and the developing roller 10d. The laser beam emitted from the laser source 86 travels through the hole 13b1, the slit 10e6, the gap between the photosensitive drum 7 and the developing roller 10dand the slit 12d, and is then received by a photoreceptor 87. The width of the laser beam received by the photoreceptor 87 is measured in a direction parallel with the face of the sheet of the drawing of FIG. 77. Therefore, the development gap can be detected.

[0337] The measurement of the gap between the photosensitive drum 7 and the developing roller 10dusing the laser beam, is effected at each of opposite longitudinal ends of the photosensitive drum 7 (two positions). Therefore, the hole 13b1, the slit and the slit 10e6, 12dare each provided at at least two positions (adjacent opposite longitudinal ends).

[0338] After the lower developing frame 12bis welded to the developing device frame 12a, the end seal 34 and the seal 35 are mounted.

[0339] As shown in FIGS. 61 and 72, the end seal 34 functions to provide a seal between the developing device frame 12aand each of the end portions of the developing blade 10eand each of the end portions of the developing roller 10d, and it comprises an arcuate portion 34acontactable to the developing roller 10dalong its circumferential surface and an integral linear portion 34balong a rear surface of each of the end portions of the metal blade 10e2. The outer circumference of the arcuate portion 34ais stuck to the sticking portion 12a20 of the developing device frame 12a.

[0340] As shown in FIG. 60, a seal 35 of urethane foam or the like is mounted and extended between blade mounting seat surfaces 12a4 formed above the toner discharging opening 12a1 of the toner discharging, and the developing blade 10eis screwed on the blade mounting seat surface 12a4 with the seal 35 therebetween. By doing so, the seal 35 is compressed between the metal blade 10e2 and a developing device frame 12aso that sealing is accomplished between the metal blade 10e2 and the developing device frame 12a.

[0341] The development holder 36 shown in FIG. 80 is secured to one of the ends of the developing device frame 12a, and the development holder 37 shown in FIG. 81 is secured to the other end thereof. The development holders 36, 37 are fixed to the developing device frame 12aby small screws 56, 57.

[0342] The shaft 10d2 of the developing roller 10dat one end is engaged with a fixed bearing 33bwhich is in the form of a shaft integral with the development holder 37 shown in FIG. 71. The developing roller shaft 10d2 is received by a bearing hole 33a2 of the bearing 33aat the other end of the developing roller 10d, and as shown in FIG. 71, a hole 33a4 is engaged with a positioning dowel 12a7 provided on the developing device frame 12aat an outside of one of the longitudinal ends. Then, the developing roller gear 10fis engaged with the developing roller shaft 10d2. The engaging portion 33a3 of the bearing 33ais engaged with a part-cylindrical engaging portion 36aof the development holder 36. At this time, the developing roller gear 10fis accommodated in the development holder 36. A small screw 56 is penetrated through a hole 36cof the development holder 36, a hole 33a1 of the bearing 33aand is threaded into a female screw 12a13 of the developing device frame 12a. The gear accommodating portion 36boutside the development holder 36 is part-cylindrical, and when the toner developing container 12 and a cleaner container 13 are coupled, the developing roller gear 10fis brought into meshing engagement with the drum gear 51athrough the open part of the gear accommodating portion 36b.

[0343] Each of the development holders 36, 37 is provided with an integral arm portion 38 functioning as a connecting portion for connecting the toner developing container 12 and the cleaner container 13.

[0344] The toner developing container 12 having the various members constituting the developing means and the cleaner container 13 having the various members constituting the photosensitive drum 7, the charging roller 8 and a cleaning means are coupled by the arm portions 38 to constitute the process cartridge B.

[0345] (Coupling Between Toner Developing Container and Cleaner Container)

[0346] Referring to FIGS. 63, 67, 80, 81, and 82, a description will be provided as to the coupling between the toner developing container 12 and the cleaner container 13. FIGS. 7 and 11 are a side view and a perspective view illustrating the coupling between the containers 12, 13; FIG. 82 shows inside of the coupling portion; and FIGS. 80 and 81 are side views of the covered end portion of the toner developing container 12. The containers 12, 13 are rotatably coupled through the arms 38 at the opposite ends. Since the covering structures at the left and right ends are substantially the same, therefore, a description will be provided as to only one end. However, the portions of the arm 38, which are different between the left and right sides, will be described for the respective ends.

[0347] At a free end portion of the arm portion 38, a through-hole 38bis provided for receiving a pin 41 which will be described hereinafter. As shown in FIG. 82, an outer wall 13qof the cleaner container 13 is provided with a hole 13cfor receiving the pin 41, and an inner wall 13dthereof is provided with a hole 13efor being press-fitted by the pin 41. The hole 13cand the hole 13eare aligned along a line parallel with the photosensitive drum 7. An elongated bore 38b1 is formed in the arm portion 38 and the other end of the cleaner container 13, and a line connecting the center of the elongated bore 38b1 and the hole 38bpasses through the centers of the holes 13c, 13e. The elongated bore 38b1 is elongated in a direction parallel with a line connecting the center of the photosensitive drum 7 and the center of the developing roller 10d, and the width of the elongated bore 38b1 is equal to the diameter of the pin 41.

[0348] When the toner developing container 12 and the cleaner container 13 are coupled together with each other, as shown in FIGS. 67 and 82, the arm portion 38 of the toner developing container 12 is inserted into the recess 13hof the cleaner container 13, and the pin 41 is penetrated through the hole 13c, 13cof the cleaner container 13, the through hole 38b, of the arm portion 38, and the elongated bore 38b1 in the order named, and is press-fitted into the holes 13e, 13eof the inner wall 13d. By doing so, the toner developing container 12 and the cleaner container 13 are rotatably coupled for rotation about the pin 41.

[0349] Because of the provision of the elongated bore 38b1, the photosensitive drum 7 and spacer rollers 1d1 of the developing roller 10dcontact each other at the generating lines thereof.

[0350] Opposite ends of a tension coil spring 59 are engaged with a spring hook 13pof the cleaner container 13 and a spring hook 12a29 of the developing device frame 12aof the toner developing container 12, respectively. The direction of the tension coil spring 59 is substantially parallel with a line connecting the centers of the photosensitive drum 7 and the developing roller 10d.

[0351] By doing so, by the tension coil spring 59, the developing roller 10dmounted in the toner developing container 12 is urged toward the photosensitive drum 7 mounted in the cleaner container 13, so that spacer rollers 10d1 at the opposite longitudinal ends of the developing roller 10dcontact the photosensitive drum 7 by which the developing roller 10dis correctly positioned relative to the photosensitive drum 7. The drum gear 51afixed to the end of the photosensitive drum 7 is brought into meshing engagement with the developing roller gear 10ffixed to the end of the developing roller 10d, so that a driving force can be transmitted.

[0352] (Remanufacturing of Process Cartridge)

[0353] (Separating Step of the Toner Developing Container and Cleaner Container)

[0354] Tension coil spring 59 shown in FIGS. 62 and 63 is removed from the locking portion 13pof the cleaner container 13.

[0355] By this, the toner developing container 12 and the cleaner container 13 are rotatable relative to each other about the pin 41.

[0356] The pin 41 is disengaged. This is done by pulling out the pin 41 using a plyer or the like if the pin 41 is projected out of the process cartridge B.

[0357] Thus, the container separating step is completed, by which the toner developing container 12 comprising the toner accommodating portion 10a, the toner supply opening 12a1, the developing roller 10dand the developing blade 10e, and the cleaner container 13 comprising the photosensitive drum 7, are separated from each other by disengaging the pins 41 at one and the other longitudinal ends of the process cartridges B.

[0358] FIG. 73 shows the thus separated toner developing container 12 and cleaner container 13.

[0359] (Removing Step of Developing Roller)

[0360] As shown in FIGS. 83 and 84, the separated toner developing container 12 includes the developing roller 10dand the developing blade 10emounted thereto.

[0361] First, the development holders 36, 37 fixed to the opposite end of the developing device frame 12aare removed. The small screw 56 fastening the development holder 36 and the bearing 33ato the developing device frame 12a, as shown in FIG. 71, is removed, and the development holder 36 is moved longitudinally outwardly. Then, the developing roller gear 10fis pulled off the developing roller shaft 10d2.

[0362] The bearing 33asupporting the developing roller 10dis removed from the shaft 10d2 of the developing roller 10d. The developing roller 10dis pulled in the actual direction to remove it from the bearing 33bof the development holder 37, and the developing roller 10dis removed from the toner developing container 12.

[0363] By doing so, the developing roller dismounting step is completed, by which the developing roller 10dmounted to the toner developing container 12 is removed.

[0364] FIG. 70 shows a state in which the developing roller 10dhas been removed. When the gear train 61 (FIG. 69) for driving the toner feeding member 10bis to be inspected, the development holder 37 is removed from the developing device frame 12aby removing the small screw 57.

[0365] (Dismounting Step of Developing Blade)

[0366] After the developing roller 10dhas been removed, the developing blade 10eis removed. The developing blade 10eis removed by unthreading the small screws 10e4 which fix the developing blade 10eto the blade mounting seat surface 12a4 (FIG. 72) of the developing device frame 12aas shown in FIG. 14, and then moving the developing blade 10eaway from the blade mounting seat surface 12a4.

[0367] Thus, the developing blade dismounting step is completed by which the developing blade 10emounted to the toner developing container 12 is separated by the separation step.

[0368] FIG. 73 is a top plan view showing the toner developing device frame 12afrom which the developing blade 10ehas been removed. FIG. 85 shows the removed developing blade 10e.

[0369] Here, all the elements that should be removed from the toner developing device frame 12ahave been removed. The drum shutter member 28 is not removed by these operations.

[0370] (Application of Sealing Material for Toner Developing Container)

[0371] If the toner seal 31 is restored, the remanufactured process cartridge is substantially the same as a new process cartridge. According to the invention, the toner seal 31 is not repaired or restored. Even without the toner seal 31, it will suffice if the toner does not leak when the developing means is mounted to the toner developing container.

[0372] (End Seal Replacing Step)

[0373] Each or one of the end seals 34 is replaced with a new one if it is confirmed as being damaged after inspection.

[0374] (Filling Sealing Material into Gap between Developing Device Frame and Lower Developing Frame)

[0375] Between the developing device frame 12aand the lower developing frame 12b, the gap g extends along the inner surface of the end seal 34 at each of the end portions. The gaps g and g1 are formed with the sealing material 39 therein as shown in FIG. 76. Sealing material 39 is a packing member such as a felt sealing between the corners receiving the developing device frame 12aand the lower developing frame 12b.

[0376] The gaps g and, g1 are first sealed. As shown in FIG. 86, sealing materials 64a, 64bare applied on both sides of the sealing material 39 appearing at the corners of the longitudinal ends of the arcuate portion 12a6 and the lower developing frame 12bextending to the outer periphery sides of the arcuate portion 12a6 and the lower developing frame 12b. At both sides of the sealing material 39, the gaps g and g1 exist.

[0377] Subsequently, the gaps g and, g1 are filled with the sealing materials 64a, 64b.

[0378] The sealing materials 64a, 64bare preferably plastically deformable sealing material. Examples of such plastically deformable sealing materials 64a, 64binclude a polymeric material having a curing property or a polymeric material having a thermoplastic property. The sealing materials include a silicon bond, which is formed by a polymeric material having a silicone-bonding-material curing property.

[0379] When the silicon bond is used as the sealing material 64, for example, the sealing material is filled, and it is left for approximately 6 hours.

[0380] (Sticking of Side Pad)

[0381] As shown in FIG. 33, a gap S exists between the longitudinal end of the elastic blade 10e1 of the developing blade 10eand the end seal 34. During the image forming operation, the toner does not leak out in the longitudinal direction by the provisions of the end seal 34 despite the existence of the gap S. However, during transportation, the toner is liable to leak out since the corner portion between the end seal 34 and a seal 35 (as will be described hereinafter, it is replaced with a blade bottom seal 35K) is a linear portion 34bof the end seal 34 so that it is not in close contact with the developing roller 10d. Therefore, a side pad is provided.

[0382] As shown in FIG. 85, a side pad 65 (seal) is stuck on the longitudinal surface of the elastic blade 10e1 of the developing blade 10eat each of the opposite end portions so as to extend beyond the longitudinal end of the blade.

[0383] The pad is stuck on the backside of the elastic blade 10e1, that is, the side not facing the developing roller 10d, using an adhesive material. The side pad 65 has such a size that it is compressed into the corner formed by the end seal 34 and a seal 35 (blade bottom seal 35K), so that it contacts them by its elasticity, and one side is substantially leveled with the free end of the elastic blade 10e1.

[0384] When the developing roller 10dis mounted, the side pad 65 provides sealing between the end seal 34 and the end of the elastic blade 10e1. The side pad 65 is press-contacted to the end seal 34 and to the seal 35.

[0385] By doing so, during transportation, the toner is prevented from leaking out through between the developing device frame 12aand the developing blade 10eat the opposite ends of the developing roller 10d.

[0386] The side pad 65 is mounted on the reused developing blade 10eif the developing blade 10eis reusable. When the developing blade 10eis to be replaced with a new part, the new part developing blade 10eis already provided with the side pad 65. In this example, the side pad 65 is made of an elastic material such as a sponge.

[0387] (Free Seal Mounting Step)

[0388] Since the seat surface of the jaw seal 42 which will be described hereinafter and the upper surface of the end seal 34 are not leveled, there is a gap between each of the opposite longitudinal ends of the jaw seal 42 and the end seal 34. In order to seal the gap, a sealing member is provided in the form of a channel shaped free seal 63k. As shown in FIG. 95, the free seal 63kis stuck on the longitudinal ends of the lower developing frame 12band the arcuate portion 12a6 of the developing device frame 12aso as to enclose the end of the end seal 34, which is opposite from the end where the toner accommodating portion 10ais provided. It is stuck with an adhesive material. The free seal 63kis made of sponge. The seal 63kcontacts the free end of the end seal 34 and the side surface containing from the free end.

[0389] (Jaw Seal Mounting Step)

[0390] After the mounting of the free seal 63kto the toner developing container 12, the jaw seal 42 is then mounted.

[0391] Jaw seal 42 is in the form of a flexible sheet.

[0392] The jaw seal 42 is stuck on the lower developing frame 12bso as to extend in the longitudinal direction of the developing roller 10dwhen the developing roller 10dis mounted to the toner developing container 12. The jaw seal 42 extends over a part of the free seal 63kand a part of the end seal 34. Each of the opposite longitudinal ends of the jaw seal 42 is cut so as not to extend beyond the free seal 63k.

[0393] The jaw seal 42 sticking seat surface 12b5, as shown in FIGS. 60, 64, is the top surface of the free and of the lower developing frame 12b. The jaw seal 42 is not stuck on the free seal 63kor the end seal 34.

[0394] (Side Cover Seal Mounting Step)

[0395] A side cover seal 69 is provided in order to reinforce the opposite longitudinal ends of the jaw seal 42 and in order to prevent toner leakage through between the longitudinal opposite ends of the seal 42 and the free seal 63kresponding thereto.

[0396] Only the opposite longitudinal end portions of the jaw seal 42 are overlapped with the free seal 63k. As shown in FIGS. 90 and 91, the side cover seal 69 is stuck on the outside of each of the opposite ends of the lower developing frame 12bso as to wind the free seal 63ktherein at a longitudinal extension of the jaw seals sticking seat surface 12b5. The width of the side cover seal 69, as shown in FIG. 91 is substantially equal to the clearance between the outside rib 12a36 on the arcuate portion 12a6 of the developing device frame 12aand the inside edge 63k1 (FIG. 95) with respect to the longitudinal direction of the free seal 63k. The side cover seal 69 is stuck using an adhesive material or an adhesive tape, from the CC part shown in FIG. 91 (edge of the sealing material 39), and is folded back along the free end portion or leading end portion (DD parts) at the longitudinal end of the portion 12b1 of the lower developing frame 12b, and is stuck so as to embrace the jaw seal 42 and the free seal 63k.

[0397] By doing so, the sealing performance at the opposite longitudinal ends of the jaw seal 42.

[0398] (Replacement of the Blade Bottom Seal)

[0399] As shown in FIG. 93, the section perpendicular to the longitudinal direction of the developing device frame 12ain the developing blade mounting surfaces 12a4 is step-shaped, and includes a recess 12a40 and a number of ribs 12a41 in the longitudinal direction. The lower part of the recess 12a40 is a flange 12a42. The upper surface of the step is an edge 12a43 with which the cap member 12cis engaged. The top surface of the edge 12a43 is slightly below the blade mounting seat surface 12a4.

[0400] When the process cartridge B is collected back, the seal 35 is bonded to the rib 12a41 and is press-contacted to the developing blade 10e(FIG. 60).

[0401] If the flange 12a42 of the developing device frame 12ais bent along the longitudinal direction, there is the liability that toner leaks through between the developing blade 10eand the developing device frame 12a. Therefore, for the collected process cartridge B, the seal 35 is peeled off after the developing roller 10dand the developing blade 10eare removed from the toner developing container 12. Then, the blade bottom seal 35k(FIG. 93) is stuck.

[0402] Here, the blade bottom seal 35khas a rectangular section, and has a thickness t such that a corner of the seal 35kis abutted to the free end of the upper surface of the flange 12a42, and another corner adjacent to the corner is abutted to the side surface of the edge 12a43.

[0403] The corners of the blade bottom seal 35kare bonded to the flange 12a42 and the edge 12a43 with an adhesive material, respectively.

[0404] After the blade bottom seal 35kis stuck, the developing blade 10eis mounted, by which the blade bottom seal 35kis compressed against the flange 12a42, continuously extending in the longitudinal direction and against the edge 12a43, so that the gap between the developing blade 10eand the developing device frame 12ais sealed.

[0405] In the foregoing, the blade bottom seal 35kwill suffice if it abuts the flange 12a42 and the edge 12a43, and therefore, the shape thereof is not limiting. Generally, it has a thickness larger than that of the seal 35 and sufficient to reach the flange 12a42 and the edge 12a43.

[0406] Blade bottom seal 35kis made of an elastic sponge member, for example.

[0407] The blade bottom sheet 35kmay be stacked on the surface of the developing blade 10eopposite from the surface contacting to the developing roller 10din place of mounting to the developing device frame 12a.

[0408] (Toner Refilling Step)

[0409] Subsequently, the toner is refilled into the toner accommodating portion 10a. As shown in FIG. 101, the toner developing container 12 is held with the toner accommodating portion 10aat the bottom with the toner supply opening 12a1 facing up. A free end of the funnel 47 is inserted through the toner supply opening 12a1, and the toner is allowed to fall into the funnel 47 from the toner bottle 48. The toner can be filled efficiently by using a metering device with an auger.

[0410] At this time, the toner filling step is completed from the toner supply opening 12a1 into the toner accommodating portion 10a.

[0411] (Mounting of Developing Blade)

[0412] The developing blade 10ehaving been removed is subjected to simultaneous air suction and air blowing, or the like such that deposited toner is removed from the blade to clean it.

[0413] Then, the developing blade 10eis inspected to determine whether it is reusable or not. If the result of the inspection indicates that the performance thereof is lower than a predetermined standard, it is replaced with a new one.

[0414] The bent portion 10e3 of the metal blade 10e2 is pressed against the flange 12a42 of the developing device frame 12aand the edge 12a43 to compress the seal 35kas shown in FIG. 93. In the state, as shown in FIG. 72, the cut 10e8 provided at each of the opposite longitudinal ends of the metal blade 10e2 is engaged with an unshown positioning dowel provided on the mounting seat surface 12a4. Then, small screws 10e4 are threaded into the developing blade mounting seat surface 12a4 through the holes 10e7 of the metal blade 10e2, thus fastening the developing blade 10eto the developing device frame 12a.

[0415] In this manner, the developing blade mounting step mounts the developing blade to the separated toner developing container 12.

[0416] (Developing Roller Mounting Step)

[0417] The developing roller 10dthat has been removed is subjected to air suction and simultaneous air blowing or another process to clean it by removing the deposited toner.

[0418] Then, the developing roller 10dis inspected, and it is determined whether or not it is reusable. If the determination is negative, that is, the its performance does not satisfy a predetermined reference standard, the developing roller is replaced with a new one.

[0419] The developing roller 10dmay be worn due to friction with the developing blade 10e. Therefore, when the statistic probability is sufficiently high that replacement is necessary on the basis of the inspections during development thereof or remanufacturing thereof, the developing roller may be replaced with a new one without the inspection, and by doing so, the remanufacturing operation is efficient.

[0420] In the inspection of the developing roller 10d, it is disassembled into the main body of the developing roller, the magnet 10c, the bearings 33a, 33b, spacer rollers 10d1, a roller electrode (unshown), the developing roller gear 10f, and so on and these elements are inspected, respectively, to find reusable parts. The non-reusable parts are replaced with new ones.

[0421] As for the gear train 61 for driving the toner feeding member 10brotatably supported on the developing device frame 12a, the development holder 37 is removed, and the gear train is cleaned and inspected, and is replaced with an usable parts, and they are reassembled prior to the assembling of the used or new developing roller 10d.

[0422] The process of mounting the developing roller 10dto the toner developing container 12 will be described.

[0423] The development holder 37 is engaged to the developing device frame 12a. A small screw 57 is threaded into the developing device frame 12athrough the development holder 37 so that development holder 37 is fixed to the developing device frame 12a. Then, a journal hole at an end of the developing roller 10dis engaged with a bearing 33bof the development holder 37. The bearing 33ais engaged in the shaft 10d2 at the other end of the developing roller 10dat the opposite longitudinal end from the bearing 33b. With this state, the hole 33a4 of the bearing 33ais aligned with the dowel 12a7 of the developing device frame 12a. Into a D-shaped shaft portion provided at the end of the shaft 10d2 of the developing roller 10dprojected outwardly beyond the bearing 33a, the developing roller gear 10fhaving a hole that has a complementary shape and size is fitted. Then, the hole 36dof the developing holder 36 is inserted into the dowel 12a7 projected from the hole 33a4 of the bearing 33a. At this time, one end of the magnet 10cis engaged with a D-shaped bole 36d, which is provided longitudinally outwardly beyond the bearing hole. The shaft portion at the end of the magnet 10chas a complementary shape and size with the D-shaped hole 36d. Then, a small screw 56 is threaded into a female screw 12a13 of the developing device frame 12athrough the hole 36cof the development holder 36 and the hole 33a1 of the bearing 33a. By doing so, the development holders 37, 36 are fixed to the developing device frame 12a, and the developing roller 10dis supported by the toner developing container.

[0424] This is the end of the process of mounting the developing roller 10dto the separated toner developing container 12.

[0425] The toner developing container 12 to which the developing roller 10dis mounted is shown in FIG. 96.

[0426] (Another Example of Toner Refilling Step)

[0427] In the foregoing examples, after the toner developing device frame 12ais subjected to the various sealing process, the toner is refilled through the toner supply opening 12a1 into the toner accommodating portion 10a. However, this is not inevitable, and the toner may be refilled into the toner developing container 12 to which the developing blade 10eand the developing roller 10dhave been mounted.

[0428] The toner is refilled through the toner filling opening 12a2 of the toner developing device frame 12ahaving been subjected to the various sealing process, and the toner filling opening 12a2 is plugged with the toner cap 32.

[0429] The toner developing container 12 filled with the toner in this manner is sealed with the sealing material 64 at the gaps g and g1 at the longitudinal ends of the developing device frame 12alower developing frame 12b, and therefore, the toner does not leak out.

[0430] The toner coming between the jaw seal (blow-out preventing seal) 42 and the end seal 34 is stopped by the free seal 63kand the side cover seal 69.

[0431] Since the side pad 65 is stuck on the elastic blade 10e1 of the developing blade 10eand is contacted to the corner formed by the seal 35kand the end seal 34, the longitudinal end of the elastic blade 10e1 is closely contacted to the developing roller 10d, and is closed by the side pad 65, and therefore, the toner is prevented from leaking out through between the longitudinal end of the elastic blade 10e1 and the end seal 34.

[0432] Therefore, the toner contained inside is not leaked out from the toner developing container 12 having the developing roller 10dand the developing blade 10emounted thereto.

[0433] The coupling process for coupling of the toner developing container 12 and the cleaner container 13 with each other is the same as the coupling step for coupling the cleaner container 13 with the toner developing container 12 having the toner seal mounted thereto. Therefore, a description will be provided referring to FIGS. 62, 63, 67, and 82.

[0434] In FIG. 67, the arm portion 38 of the toner developing container 12 is inserted into the recess 13hof the cleaner container 13. As shown in FIG. 82, the through hole 38b(elongated bore 38b1) of the arm portion 38 is aligned with the hole 13cformed in the outer wall surface 13qof the cleaner container 13. When the hole 13cand the through hole 38b(elongated bore 38b1) are aligned, the through hole 38bis aligned with the hole 13ein the inner wall surface 13dof the cleaner container 13. Here, the pin 41 is inserted into the hole 13cof the outer wall surface 13qof the cleaner container 13 and the hole 38b(elongated bore 38b1) of the arm portion 38 of the toner developing container 12. Additionally, the pin 41 is press-fitted into the hole 13eof the inner wall surface 13dof the cleaner container 13. The tension coil spring 59 is stretched between the spring hook 12a29 of the toner developing container 12 and the spring hook 13pof the cleaner container 13. By doing so, the spacer roller 10d1 provided adjacent to the opposite longitudinal ends of the developing roller 10dare contacted to the photosensitive drum 7.

[0435] In this manner, the process cartridge can be remanufactured without attaching the toner seal.

[0436] (Remanufacturing of Cleaning Container)

[0437] When the toner developing container 12 is remanufactured, the separated cleaner container 13 is remanufactured. The remanufacturing of the cleaner container is similar to Embodiment 1, and therefore, the description thereof is omitted.

[0438] (Gap between Photosensitive Drum and Developing Roller)

[0439] When the photosensitive drum 7 and the developing roller 10dcontact each other, the drum gear 51aand the developing roller gear 10fin meshing engagement with each other. When the process cartridge is transported with the drum gear 51aand the developing roller gear 10fin meshing engagement with each other, the tooth surfaces of the gears are in contact, and therefore, they may be rotated by impact or vibration. If the direction of the rotation is as indicated by an arrow AAA in FIG. 52 (the same direction as in the image forming operation), there is no problem. However, the direction of the rotation is not assured, since vibration or impact during the transportation occurs at random. If the photosensitive drum 7 rotates in the direction indicated by an arrow BBB, that is, if the photosensitive drum 7 and the developing roller 10dare rotated in the direction opposite from the normal direction, the toner may leak out through between the jaw seal 42 (blow-out preventing sheet) and the developing roller 10d. and in the worst-case, the seal 42 may be wound around the developing roller since the preventing sheet contacts the developing roller counter-directionally. In addition, the scraper 60 mounted to each of the opposite ends of the developing blade 10eand functioning to guide the toner inwardly at the opposite ends of the developing roller 10dcan operate correctly when the developing roller 10drotates in the normal direction, and therefore, if it is rotated in the wrong direction, the toner may leak out at the opposite ends of the developing roller 10d.

[0440] In this embodiment, the back clearance of the meshing between the drum gear 51aand the developing roller gear 10fis made larger than that during the image formation to avoid abutment between the tooth surfaces during the transportation. They may be disengaged from each other.

[0441] Referring to FIG. 98, a description will be provided as to means for maintaining the disengaged state or a large back clearance between the drum gear 51aand the developing roller gear 10f. In the case of FIG. 53, a tape 81 is stuck over the toner developing container 12 and the cleaner container 13 with the drum gear 5 la and the developing roller gear 10fdisengaged from each other or with the large back clearance.

[0442] More particularly, a force is applied to bias the toner developing container 12 and the cleaner container 13 toward each other at positions across a vertical surface passing through a point P, which is a pivot between the toner developing container 12 and the cleaner container 13, from the portion where the photosensitive drum 7 and the developing roller 10dare provided, as indicated by an arrow N in FIG. 53, by which the back clearance between the drum gear 51aand the developing roller gear 10fis increased, or they are disengaged from each other. The force is opposed by the spring force provided by the tension coil spring 59 (FIG. 7) and the compression coil spring 40 (FIG. 11) for urging the photosensitive drum 7 and the developing roller 10dtoward each other. Therefore, the tape 81 is stretched by the springs 40, 59. Therefore, the tape 81 has sufficient width and thickness such that stress during the transportation is within a tolerable range, and in addition, the adhesive material or the adhesive material for the tape has also sufficient bonding strength against the toner developing device frame 12aand the cleaner container 13.

[0443] The embodiments of the present invention are summarized as follows.

[0444] 1. A remanufacturing method of remanufacting a process cartridge B comprising:

[0445] (a) a step of preparing a used process cartridge B which comprises a toner developing container 12, a cleaning container 13 and pins for coupling the toner developing container 12 and the cleaning container 13 at opposite longitudinal ends of the process cartridge B,

[0446] the toner developing container 12 including a toner accommodating portion 10a, a toner supply opening 12a1, a developing roller 10dand a developing blade 10e;

[0447] the cleaning container 13 including an electrophotographic photosensitive drum 7;

[0448] (b) a container separating step of separating the process cartridge B into the toner developing container 12 and the cleaning container by disengaging the pins from the process cartridge B;

[0449] (c) a developing roller 10ddismounting step of dismounting the developing roller 10dfrom the toner developing container 12 separated by the container separating step;

[0450] (d) a developing blade 10edismounting step of dismounting the developing blade 10efrom the toner developing container 12 separated by the container separating step;

[0451] (e) a sealing material 64 filling step of filling a sealing material 64 into a gap formed in the toner developing container 12 extending longitudinally inside of an end seal 34 provided at each of longitudinally opposite ends thereof;

[0452] (f) a developing blade 10emounting step of mounting the developing blade 10eon the toner developer container having the sealing material 64;

[0453] (g) a developing roller 10dmounting step of mounting the developing roller 10don the toner developer container having the sealing material 64;

[0454] (h) a toner refilling step of refilling the toner into the toner accommodating portion 10aof the toner developing container 12 having the sealing material 64, the developing blade 10eand the developing roller 10d; and

[0455] (i) a container coupling step of coupling the toner developing container 12 having the sealing material 64, the developing blade 10eand the developing roller 10dwith the cleaning container 13 by engaging the pin 41 into them.

[0456] 2. A remanufacturing method of remanufacting a process cartridge B comprising:

[0457] (a) a step of preparing a used process cartridge B which comprises a toner developing container 12, a cleaning container 13 and pins for coupling the toner developing container 12 and the cleaning container 13 at opposite longitudinal ends of the process cartridge B,

[0458] the toner developing container 12 including a toner accommodating portion 10a, a toner supply opening 12a1, a developing roller 10dand a developing blade 10e;

[0459] the cleaning container 13 including an electrophotographic photosensitive drum 7;

[0460] (b) a container separating step of separating the process cartridge B into the toner developing container 12 and the cleaning container by disengaging the pins from the process cartridge B;

[0461] (c) a developing roller 10ddismounting step of dismounting the developing roller 10dfrom the toner developing container 12 separated by the container separating step;

[0462] (d) a developing blade 10edismounting step of dismounting the developing blade 10efrom the toner developing container 12 separated by the container separating step;

[0463] (e) a sealing material 64 filling step of filling a sealing material 64 into a gap formed in the toner developing container 12 extending longitudinally inside of an end seal 34 provided at each of longitudinally opposite ends thereof;

[0464] (f) a sealing material 64 applying step of applying a sealing material 64 to cover a portion of a sealing member exposed from the toner developing container 12, the sealing member being the provided at each of the opposite longitudinal ends at a position remote from the developing roller 10d;

[0465] (g) a developing blade 10emounting step of mounting the developing blade 10eon the toner developer container having the sealing material 64;

[0466] (h) a developing roller 10dmounting step of mounting the developing roller 10don the toner developer container having the sealing material 64;

[0467] (i) a toner refilling step of refilling the toner into the toner accommodating portion 10aof the toner developing container 12 having the sealing material 64, the developing blade 10eand the developing roller 10d; and

[0468] (j) a container coupling step of coupling the toner developing container 12 having the sealing material 64, the developing blade 10eand the developing roller 10dwith the cleaning container 13 by engaging the pin 41 into them.

[0469] 3. A method according to Paragraph 1 or 2, wherein in the sealing material 64 filling step, the sealing material 64 is injected to a middle portion of a length of the gap, and then is expanded toward ends of the length.

[0470] 4. A method according to any one of Paragraphs 1 to 3, wherein the sealing member is a plastically deformable sealing material 64.

[0471] 5. A method according to Paragraph 4, wherein the sealing material 64 is a high polymer material having a curing property or a thermoplastic high polymer material.

[0472] 6. A method according to Paragraph 5, wherein the sealing material 64 is silicone bond or hot melt plastic material.

[0473] 7. A method according to any one of Paragraphs 1 to 6, wherein the toner refilling step is carried out after the sealing material 64 sealing step and before the developing blade 10emounting step and the developing roller 10dmounting step, and wherein the toner refilling step is effected through a toner supply opening 12a1 for supplying the toner from the toner accommodating portion 10ato the developing roller 10d.

[0474] 8. A method according to any one of Paragraphs 1 to 6, wherein the toner refilling step is carried out after the sealing material 64 filling step, said developing blade 10emounting step and the developing roller 10dmounting step, and wherein the toner refilling step is effected through a toner filling opening.

[0475] 9. A method according to any one of Paragraphs 1 to 8, wherein in the developing blade 10emounting step, a new blade or a used blade is used.

[0476] 10. A method according to any one of Paragraphs 1 to 9, wherein in the developing roller 10dmounting step, a new roller or a used roller is used.

[0477] 11. A method according to any one of Paragraphs 1 to 10, wherein the electrophotographic photosensitive drum 7 and the cleaning blade are removed from the cleaning container 13, and the toner contained in the cleaning container 13 and having been removed from the electrophotographic photosensitive drum 7 is removed, before the coupling step.

[0478] 12. A method according to Paragraph 11, wherein after the toner is removed, a new or used electrophotographic photosensitive drum 7 and a new or used cleaning blade is mounted.

[0479] 13. A method according to any one of Paragraphs 1 to 12, wherein the remanufacturing method is implemented with a toner seal for sealing a toner supply opening 12a1 provided to supply the toner accommodated in the toner accommodating portion 10ato the developing roller 10dhaving been pulled out to supply toner accommodated in said toner accommodating portion 10ato the developing roller 10d.

[0480] 14. A method according to any one of Paragraphs 1 or 2, wherein the process cartridge B comprises a gear fixed co-axially with the electrophotographic photosensitive drum 7 and a gear fixed co-axially with the developing roller 10d, which gears are in meshing engagement, and wherein after the container coupling process, the toner developing container 12 and the cleaner container are rotated about the pin 41 to disengage the gears from each other or to make a back clearance of the meshing engagement larger than that during the image forming operation, and the disengagement or larger back clearance is maintained.

[0481] 15. A method according to Paragraph 14, wherein the toner developing container 12 and the cleaner container are rotated toward each other about the pin 41 at a portion across the pin 41 from the electrophotographic photosensitive drum 7, and a tape is stuck on the toner developing container 12 and the cleaner container to maintain the disengagement or the larger back clearance.

[0482] As described in the foregoing, according to the present invention, an easy remanufacturing method for a process cartridge is provided.

[0483] Furthermore, a remanufacturing method for a process cartridge by which the toner leakage can be effectively prevented is provided.

[0484] While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth and this application is intended to cover such modifications or changes as may come within the purposes of the improvements; or the scope of the following claims.