Process cartridge and drum cartridge

This application claims priority from Japanese Patent Application No. 2015-022607 filed Feb. 6, 2015. The entire content of the priority application is incorporated herein by reference.

The present disclosure relates to a process cartridge and a drum cartridge mountable in an electro-photographic image forming apparatus.

As a process cartridge mountable in an electro-photographic image forming apparatus, there has been proposed a process cartridge that includes a photosensitive cartridge and a developing cartridge attachable to the photosensitive cartridge. The photosensitive cartridge includes a photosensitive drum, and the developing cartridge includes a developing roller (for example, see Japanese Patent Application Publication No. 2011-197197).

In this process cartridge, the photosensitive cartridge includes a pressing portion, and the developing cartridge includes a pressed portion configured to be pressed by the pressing portion. Pressing the pressed portion by the pressing portion causes the developing roller to be pressed against the photosensitive drum.

In an effort to increase an amount of toner stored in the developing cartridge, the developing cartridge may be made larger in size in a direction away from the photosensitive drum, without providing a wall bridging between left and right side walls supporting the photosensitive drum on one end of the photosensitive cartridge remote from the photosensitive drum.

However, if the wall bridging the right and left side walls were not provided, degradation in rigidity of the photosensitive cartridge would be expected.

Further, in this case, if the pressing portion is positioned excessively far away from the photosensitive drum, a reaction force generated by the pressing portion pressing the pressed portion may cause deformation of the photosensitive cartridge. Such deformation of the photosensitive cartridge would make it difficult to appropriately press the developing roller against the photosensitive drum.

In view of the foregoing, it is an object of the disclosure to provide a process cartridge and a drum cartridge capable of stably pressing a developing roller against a photosensitive drum even if an amount of stored developer is increased.

In order to attain the above and other objects, the disclosure provides a process cartridge including a drum cartridge and a developing cartridge attachable to and detachable from the drum cartridge. The developing cartridge includes a developing roller, a pressing protrusion and an engagement protrusion. The drum cartridge includes a photosensitive drum, a locking member engageable with the engagement protrusion of the developing cartridge attached to the drum cartridge, and a pressing member disposed between the locking member and the photosensitive drum. The locking member is pivotable between a restricting position engaged with the engagement protrusion to restrict detachment of the developing cartridge from the drum cartridge and a non-restricting position disengaged from the engagement protrusion to allow detachment of the developing cartridge from the drum cartridge. The pressing member is configured to contact the pressing protrusion of the developing cartridge attached to the drum cartridge for pressing the developing cartridge toward the photosensitive drum.

According to another aspect, the disclosure provides a drum cartridge to which a developing cartridge including a developing roller is detachably attachable. The drum cartridge includes a photosensitive drum, a locking member and a pressing member disposed between the locking member and the photosensitive drum. The locking member is configured to pivot between a restricting position engaged with the developing cartridge to restrict detachment of the developing cartridge and a non-restricting position disengaged from the developing cartridge to allow detachment of the developing cartridge. The pressing member is configured to press the developing roller toward the photosensitive drum when the developing cartridge is attached to the drum cartridge.

According to still another aspect, the disclosure provides a drum cartridge including a photosensitive drum, a pivotally movable locking lever and a spring disposed between the locking member and the photosensitive drum. The locking lever includes a shaft having a peripheral surface, and an operation arm extending from the peripheral surface of the shaft. The operation arm includes a base and a claw extending from the base toward the photosensitive drum.

The particular features and advantages of the disclosure as well as other objects will become apparent from the following description taken in connection with the accompanying drawings, in which:

FIG. 1 is a perspective view showing a general construction of a process cartridge according to an embodiment as viewed from an upper-front perspective, the process cartridge including a drum cartridge and a developing cartridge;

FIG. 2 is a perspective view of the drum cartridge according to the embodiment as viewed from an upper-front perspective;

FIG. 3 is a partially-enlarged perspective view showing a right end portion of the drum cartridge according to the embodiment as viewed from an upper-rear perspective, wherein a locking member and a torsion spring are removed from the drum cartridge;

FIG. 4 is a cross-sectional view of the drum cartridge according to the embodiment taken along a plane A-A shown in FIG. 11 ;

FIG. 5 is a perspective view of the developing cartridge according to the embodiment as viewed from an upper-rear perspective;

FIG. 6 is a perspective view of the developing cartridge according to the embodiment as viewed from a lower-front perspective;

FIG. 7 is a bottom view of the developing cartridge according to the embodiment;

FIG. 8 is a perspective view showing a developing frame of the developing cartridge according to the embodiment as viewed from an upper-rear perspective;

FIG. 9 is a partially enlarged cross-sectional view showing a portion of the developing frame of the developing cartridge according to the embodiment taken along a plane B-B shown in FIG. 7 ;

FIG. 10 is a plan view of the process cartridge according to the embodiment;

FIG. 11 is a cross-sectional view showing an internal structure of the process cartridge according to the embodiment taken along a plane C-C shown in FIG. 10 ;

FIG. 12 is a cross-sectional view showing the internal structure of the process cartridge according to the embodiment taken along a plane D-D shown in FIG. 10 ;

FIG. 13 is an explanatory view illustrating detachment of the developing cartridge from the drum cartridge according to the embodiment after the state of FIG. 12 , wherein the locking member is pivotally moved counterclockwise to bring a lifting part into contact with a contact protrusion of the developing cartridge;

FIG. 14 is an explanatory view illustrating detachment of the developing cartridge from the drum cartridge according to the embodiment after the state of FIG. 13 , wherein the developing cartridge is pivotally moved clockwise to bring an upper rear portion of a side wall of the developing frame into contact with a contact part of the drum cartridge;

FIG. 15 is an explanatory view illustrating detachment of the developing cartridge from the drum cartridge according to the embodiment after the state of FIG. 14 , wherein the locking member is in its non-restricting position and a pressing protrusion of the developing cartridge is disengaged upward from a pressing member of the drum cartridge; and

FIG. 16 is a schematic vertical cross-sectional view of an image forming apparatus in which the process cartridge according to the embodiment is mounted.

1. Overall Structure of Process Cartridge

A process cartridge 1 according to an embodiment will be described first while referring to FIGS. 1 through 16 .

In the following description, directions in relation to the process cartridge 1 will be based on a state where the process cartridge 1 is resting on a horizontal plane. Thus up-down direction of the process cartridge 1 corresponds to the vertical direction. Specifically, directions of the process cartridge 1 are indicated by arrows shown in FIG. 1 .

As illustrated in FIGS. 1 and 16 , the process cartridge 1 includes a drum cartridge 2 and a developing cartridge 3 .

The drum cartridge 2 includes a photosensitive drum 4 , a scorotron charger 5 , and a transfer roller 6 .

The photosensitive drum 4 is rotatably supported by a rear end portion of the drum cartridge 2 . The photosensitive drum 4 has a cylindrical shape that extends in a left-right direction. The photosensitive drum 4 defines a rotation axis A 1 extending in the left-right direction.

The scorotron charger 5 is arranged rearward and upward of the photosensitive drum 4 and is separated therefrom.

The transfer roller 6 is disposed below the photosensitive drum 4 and is in contact with a lower end portion of the photosensitive drum 4 .

The developing cartridge 3 is attachable to and detachable from the drum cartridge 2 . When attached to the drum cartridge 2 , the developing cartridge 3 is positioned frontward of the photosensitive drum 4 . The developing cartridge 3 includes a developing roller 7 , a supply roller 8 , a thickness regulation blade 9 , and a toner storage portion 10 .

The developing roller 7 is rotatably supported by a rear end portion of the developing cartridge 3 . The developing roller 7 includes a developing-roller shaft 7 A and a developing-roller body 7 B.

The developing-roller shaft 7 A has a columnar shape and extends in the left-right direction. That is, the developing-roller shaft 7 A defines a rotation axis A 2 extending in the left-right direction. The developing-roller shaft 7 A is made of a metal.

The developing-roller body 7 B has a cylindrical shape and extends in the left-right direction. The developing-roller body 7 B is formed of an electrically conductive rubber. The developing-roller body 7 B does not cover both end portions of the developing-roller shaft 7 A, but covers a center portion of the developing-roller shaft 7 A in the left-right direction. In the process cartridge 1 (when the developing cartridge 3 is attached to the drum cartridge 2 ), the developing-roller body 7 B is in contact with a front end portion of the photosensitive drum 4 .

The supply roller 8 is rotatably supported in the developing cartridge 3 at a position frontward and downward of the developing roller 7 . The supply roller 8 includes a supply-roller shaft 8 A and a supply-roller body 8 B.

The supply-roller shaft 8 A has a columnar shape and extends in the left-right direction. The supply-roller shaft 8 A is formed of a metal.

The supply-roller body 8 B has a cylindrical shape. The supply-roller body 8 B extends in the left-right direction. The supply-roller body 8 B is formed of a sponge having an electrically conductive property. The supply-roller body 8 B does not cover both end portions of the supply-roller shaft 8 A, but covers a center portion of the supply-roller shaft 8 A in the left-right direction. The supply-roller body 8 B is in contact with a lower front end portion of the developing-roller body 7 B.

The thickness regulation blade 9 is disposed upward and frontward of the developing roller 7 . The thickness regulation blade 9 contacts a front end portion of the developing-roller body 7 B.

The toner storage portion 10 is disposed forward of the supply roller 8 and the thickness regulation blade 9 . The toner storage portion 10 is adapted to store toner. The toner storage portion 10 includes an agitator 11 .

The agitator 11 is rotatably supported within the toner storage portion 10 . The agitator 11 includes an agitator shaft 11 A and a blade 11 B.

The agitator shaft 11 A has a columnar shape extending in the left-right direction. That is, the agitator shaft 11 A defines a rotation axis A 3 extending in the left-right direction.

The blade 11 B extends radially outward from an outer peripheral surface of the agitator shaft 11 A.

2. Detailed Structure of Drum Cartridge

As illustrated in FIG. 2 , the drum cartridge 2 has a tray-like shape whose front and upper end portions are open. The drum cartridge 2 has a rectangular shape in a plan view. The drum cartridge 2 mainly includes a drum frame 21 , a pair of pressing members 26 L and 26 R, a locking member (locking lever) 27 , and a pair of rollers 28 .

(1) Drum Frame

The drum frame 21 includes a base frame 22 and a cover frame 23 .

(1-1) Base Frame

The base frame 22 constitutes a lower half of the drum frame 21 . The base frame 22 includes a pair of side walls 24 L and 24 R, and a lower wall 25 , but is not provided with a front wall.

The side wall 24 L constitutes a left end portion of the base frame 22 . The side wall 24 L has a generally rectangular plate-like shape and extends in a front-rear direction in a side view. The side wall 24 L includes a guide groove 29 L.

The guide groove 29 L is formed in a center portion of the side wall 24 L in the front-rear direction. The guide groove 29 L is recessed downward from an upper edge of the side wall 24 L and has a generally U shape that is open upward in a side view. The guide groove 29 L includes a first guide surface 30 A, a second guide surface 30 B, and a fitting part 30 C.

The first guide surface 30 A is a peripheral surface of a frontward portion constituting the guide groove 29 L. The first guide surface 30 A extends rearward and downward from the upper edge of the side wall 24 L.

The second guide surface 30 B is a peripheral surface of a lower portion constituting the guide groove 29 L. The second guide surface 30 B is connected to a lower end of the first guide surface 30 A and extends rearward therefrom.

The fitting part 30 C is disposed on a lower-rear end of the guide groove 29 L. The fitting part 30 C is a groove that is recessed rearward from the peripheral surface of a rearward portion constituting the guide groove 29 L. That is, in a side view, the fitting part 30 C has a generally U-shape whose front end is opened. The fitting part 30 C has a lower surface that is connected to the second guide surface 30 B.

As illustrated in FIGS. 2 and 3 , the side wall 24 R constitutes a right end portion of the base frame 22 . The side wall 24 R has a rectangular plate shape in a side view and extends in the front-rear direction. The side wall 24 R includes a guide groove 29 R, a lock support hole 32 , and a locking protrusion 33 .

The guide groove 29 R is arranged at a generally center portion of the side wall 24 R in the front-rear direction. The guide groove 29 R is recessed downward from an upper peripheral edge of the side wall 24 R. The guide groove 29 R has a general U-shape that is open upward in a side view. The guide groove 29 R includes a first guide surface 31 A, a second guide surface 31 B, and a fitting part 31 C.

The first guide surface 31 A is a peripheral surface of a frontward portion constituting the guide groove 29 R. The first guide surface 31 A extends rearward and downward from the upper peripheral edge of the side wall 24 R.

The second guide surface 31 B is a peripheral surface of a lower portion constituting the guide groove 29 R. The second guide surface 31 B is connected to a lower end of the first guide surface 31 A and extends rearward therefrom.

The fitting part 31 C is disposed on a lower-rear end of the guide groove 29 R. The fitting part 31 C is a groove that is recessed rearward from a peripheral surface of a rearward portion constituting the guide groove 29 R. The fitting part 31 C has a general U-shape that is open frontward in a side view. The fitting part 31 C has a lower surface that is connected to the second guide surface 31 B.

The lock support hole 32 is formed in a front end portion of the side wall 24 R. The lock support hole 32 penetrates the side wall 24 R in the left-right direction and has a circular shape in a side view.

The locking protrusion 33 is disposed generally below the lock support hole 32 . The locking protrusion 33 extends leftward from a left surface of the side wall 24 R and has a left end portion that is bent downward. The locking protrusion 33 thus has a hook-like shape.

As illustrated in FIGS. 2 and 4 , the lower wall 25 is arranged to connect between lower ends of the side wall 24 L and the side wall 24 R. The lower wall 25 extends in the left-right direction and has a rectangular plate shape in a top view.

The lower wall 25 has a left end that is connected to the lower end of the side wall 24 L, and a right end that is connected to the lower end of the side wall 24 R. The lower wall 25 includes a pressing support portion 34 L, a pressing support portion 34 R and a wall portion 35 .

The pressing support portion 34 L is disposed on a left end portion of the lower wall 25 . The pressing support portion 34 L is arranged frontward of the guide groove 29 L. The pressing support portion 34 L extends upward from an upper surface of the lower wall 25 . The pressing support portion 34 L has a rectangular cylindrical shape whose rear end portion is open. The pressing support portion 34 L includes a front wall 36 A, a left wall 36 B, and a right wall 36 C.

The front wall 36 A constitutes a front end portion of the pressing support portion 34 L. The front wall 36 A extends in the left-right direction and has a rectangular plate-like shape in the front view.

The left wall 36 B constitutes a left end portion of the pressing support portion 34 L. The left wall 36 B extends in the front-rear direction and has a rectangular plate-like shape in a side view. The left wall 36 B has a front end that is connected to a left end of the front wall 36 A.

The right wall 36 C constitutes a right end portion of the pressing support portion 34 L. The right wall 36 C extends in the front-rear direction and has a rectangular plate-like shape in a side view. The right wall 36 C has a front end that is connected to a right end of the front wall 36 A.

The pressing support portion 34 L is configured to movably receive the pressing member 26 L therein for guiding movement of the pressing member 26 L in the front-rear direction, as will be described later.

The pressing support portion 34 R is disposed on a right end portion of the lower wall 25 . The pressing support portion 34 R is arranged frontward of the guide groove 29 R and rearward of the lock support hole 32 (see FIG. 3 ) such that the pressing support portion 34 R is aligned with the pressing support portion 34 L in the left-right direction (or, put other way, the pressing support portion 34 R and pressing support portion 34 L are coincident with each other when viewed in the left-right direction). That is, the pressing support portion 34 R is disposed between the photosensitive drum 4 and the lock support hole 32 in the front-rear direction.

The pressing support portion 34 R extends upward from the upper surface of the lower wall 25 , and has a rectangular cylindrical shape whose rear end is open. The pressing support portion 34 R includes a front wall 37 A, a left wall 37 B, and a right wall 37 C.

The front wall 37 A constitutes a front end portion of the pressing support portion 34 R. The front wall 37 A extends in the left-right direction and has a rectangular plate-like shape in a front view.

The left wall 37 B constitutes a left end portion of the pressing support portion 34 R. The left wall 37 B extends in the front-rear direction and has a rectangular plate-like shape in a side view. The left wall 37 B has a front end that is connected to a left end of the front wall 37 A.

The right wall 37 C constitutes a right end portion of the pressing support portion 34 R. The right wall 37 C extends in the front-rear direction and has a rectangular plate-like shape in a side view. The right wall 37 C has a front end that is connected to a right end of the front wall 37 A.

The pressing support portion 34 R is configured to movably receive the pressing member 26 R therein for guiding movement of the pressing member 26 R in the front-rear direction, as will be described later.

The wall portion 35 is provided at a front end portion of the lower wall 25 on the right end thereof. The wall portion 35 is disposed leftward of the side wall 24 R to be spaced away therefrom. The wall portion 35 is positioned frontward of the lock support hole 32 . The wall portion 35 extends upward from the upper surface of the lower wall 25 . The wall portion 35 extends in the front-rear direction and has a rectangular plate-like shape in a side view.

(1-2) Cover Frame

As illustrated in FIG. 2 , the cover frame 23 is disposed upward of a rear end portion of the base frame 22 for covering the photosensitive drum 4 . The cover frame 23 supports the scorotron charger 5 . The cover frame 23 includes a contact part 50 .

The contact part 50 is arranged at a front end portion of the cover frame 23 on a right end thereof. The contact part 50 extends downward from an upper wall constituting of the cover frame 23 . The contact part 50 has a rectangular cylindrical shape. The contact part 50 has a front surface 50 A that is flat and extends in an up-down direction.

In the drum cartridge 2 , the cover frame 23 , a rear end portion of the side wall 24 L, a rear end portion of the side wall 24 L and a rear end portion of the lower wall 25 define a drum supporting section 48 . The drum supporting section 48 is a box-shaped section for supporting the photosensitive drum 4 .

Further, in the drum cartridge 2 , a tray-shaped portion positioned frontward of the drum supporting section 48 serves as a developing cartridge attachment section 49 to which the developing cartridge 3 is attached. That is, the developing cartridge attachment section 49 is defined by a frontward portion of the side wall 24 L, a frontward portion of the side wall 24 R, and a frontward portion of the lower wall 25 .

(2) Pressing Members

Referring to FIG. 4 , the pressing member 26 L is disposed between the left wall 36 B and the right wall 36 C constituting the pressing support portion 34 L. The pressing member 26 L is configured to abut against a pressing protrusion 60 L of the developing cartridge 3 (described later) for pressing the developing cartridge 3 toward the photosensitive drum 4 . The pressing member 26 L has a rectangular cylindrical shape whose rear end is closed. The pressing member 26 L has a rear surface 40 that is a flat surface extending in the up-down direction and left-right direction. A compression spring 39 L is arranged between a rear wall of the pressing member 26 L and the front wall 36 A of the pressing support portion 34 L. The pressing member 26 L is thus normally urged rearward by the compression spring 39 L.

The pressing member 26 R is disposed between the photosensitive drum 4 and the locking member 27 in the front-rear direction. Referring to FIG. 4 , the pressing member 26 R is disposed between the left wall 37 B and the right wall 37 C of the pressing support portion 34 R. The pressing member 26 R is configured to contact a pressing protrusion 60 R of the developing cartridge 3 (described later) for pressing the developing cartridge 3 toward the photosensitive drum 4 . The pressing member 26 R has a rectangular cylindrical shape whose rear end is closed. The pressing member 26 R has a rear surface 41 that is a flat surface extending in the up-down direction and left-right direction. A compression spring 39 R is arranged between a rear wall of the pressing member 26 R and the front wall 37 A of the pressing support portion 34 R. The pressing member 26 R is thus normally urged rearward by the compression spring 39 R. The compression spring 39 R is positioned between the photosensitive drum 4 and the locking member 27 in the front-rear direction. That is, the compression spring 39 R is disposed between the locking member 27 and the pressing member 26 R in the front-rear direction.

(3) Locking Member and Tension Spring

As illustrated in FIGS. 2 and 3 , the locking member 27 is supported by a front end portion of the side wall 24 R. The locking member 27 is positioned between the side wall 24 R and the wall portion 35 in the left-right direction. More specifically, the locking member 27 is configured to pivot between a restricting position (see FIG. 12 ) and a non-restricting position (see FIG. 15 ). In the restricting position, the locking member 27 engages an engagement protrusion 64 of the developing cartridge 3 (described later) to restrict detachment of the developing cartridge 3 from the drum cartridge 2 . In the non-restricting position, the locking member 27 is disengaged from the engagement protrusion 64 to allow detachment of the developing cartridge 3 from the drum cartridge 2 .

Hereinafter, the locking member 27 will be described based on an assumption that the locking member 27 is at the restricting position. The locking member 27 includes: a shaft 42 ; an operation arm including a restricting part 43 and an operation part 44 ; and a lift arm including a lifting part 45 and a locking protrusion 46 .

The shaft 42 has a columnar shape extending in the left-right direction. The shaft 42 is rotatably fitted into the lock support hole 32 formed in the side wall 24 R.

The restricting part 43 extends upward from an upper peripheral surface of the shaft 42 . The restricting part 43 includes a claw 43 A and a base 43 B.

The base 43 B has a rectangular cylindrical shape that extends in the left-right direction. The base 43 B has a lower end that is connected to the upper peripheral surface of the shaft 42 . The claw 43 A protrudes rearward and downward from an upper end portion of the base 43 B. That is, the claw 43 A extends from the upper end portion of the base 43 B toward the photosensitive drum 4 . The claw 43 A has a wedge-like shape whose lower rear end portion constitutes an apex in a side view.

The operation part 44 extends forward from an upper end portion of the restricting part 43 (claw 43 A) and has a rectangular plate-like shape in a plan view. The operation part 44 has a front end portion that is positioned rightward of the wall portion 35 to oppose the wall portion 35 , when the locking member 27 is at the restricting position.

The lifting part 45 extends rearward and downward from a lower peripheral surface of the shaft 42 and has a rectangular plate-like shape in a plan view.

The locking protrusion 46 extends rightward from a right surface of the lifting part 45 and has a right end portion that is bent upward to provide a hook-like shape.

A tension spring (urging member) 47 is provided between the locking member 27 and the side wall 24 R to urge the locking member 27 toward the restricting position. The tension spring 47 is a tension coil spring that extends in the up-down direction. The tension spring 47 has an upper end engaged with the locking protrusion 46 of the locking member 27 , and has a lower end engaged with the locking protrusion 33 of the side wall 24 R. The tension spring 47 has a natural length when the locking member 27 is at the restricting position.

(4) Rollers, Grip Part and Conveying Roller

The pair of rollers 28 is disposed one on respective left and right end portions of a frond end portion of the lower wall 25 . The rollers 28 have a columnar shape that extends in the left-right direction. The rollers 28 are rotatably supported on an upper surface of the lower wall 25 . That is, the rollers 28 are positioned such that the locking member 27 is disposed between the rollers 28 and the photosensitive drum 4 in the front-rear direction.

A grip part 38 is formed on a center portion of the front end portion of the lower wall 25 in the left-right direction. The grip part 38 has an upper surface that is lower than upper end portions of the rollers 28 .

Further, a conveying roller 100 is disposed on a lower surface of the lower wall 25 at a position generally center in the front-rear direction. The conveying roller 100 has a columnar shape that extends in the left-right direction. The conveying roller 100 has a left end that protrudes leftward relative to the side wall 24 L, and a right end that protrudes rightward relative to the side wall 24 R.

3. Detailed Structure of the Developing Cartridge

As illustrated in FIGS. 5 and 6 , the developing cartridge 3 includes a developing frame 51 and a drive part 52 .

(1) Developing Frame

As illustrated in FIGS. 6 and 8 , the developing frame 51 has a box-like shape. The developing frame 51 includes the toner storage portion 10 , and supports the developing roller 7 , the supply roller 8 , and the thickness regulation blade 9 . The developing frame 51 includes a pair of side walls 53 L and 53 R, a lower wall 54 , a front wall 55 , and an upper wall 56 .

As illustrated in FIG. 8 , the side wall 53 L constitutes a left end portion of the developing frame 51 . The side wall 53 L has a rectangular plate-like shape that extends in the front-rear direction in a side view. The side wall 53 L includes the pressing protrusion 60 L configured to be pressed by the pressing member 26 L when the developing cartridge 3 is attached to the drum cartridge 2 .

The pressing protrusion 60 L is arranged on a lower end portion of the side wall 53 L generally below the agitator shaft 11 A. The pressing protrusion 60 L extends leftward from a left surface of the side wall 53 L and has a general U-shape that is open rearward in a side view. The pressing protrusion 60 L has a curved front surface 61 whose center portion in the up-down direction projects frontward.

As illustrated in FIGS. 6 and 12 , the side wall 53 R constitutes a right end portion of the developing frame 51 . The side wall 53 R has a rectangular plate-like shape that extends in the front-rear direction in a side view. The side wall 53 R includes the pressing protrusion 60 R, a contact protrusion 63 , the engagement protrusion 64 , and a contact part 101 .

The pressing protrusion 60 R is arranged on a lower end portion of the side wall 53 R at a position coincident with the pressing protrusion 60 L when viewed in the left-right direction. That is, the pressing protrusion 60 R and pressing protrusion 60 L are aligned with each other in the left-right direction. The pressing protrusion 60 R extends rightward from a right surface of the side wall 53 R and has a general U-shape that is open rearward in a side view. The pressing protrusion 60 R has a curved front surface 62 whose center portion in the up-down direction projects forward.

The contact protrusion 63 is disposed frontward of the pressing protrusion 60 R. The contact protrusion 63 extends rightward from the right surface of the side wall 53 R and has a generally L-shape in a side view.

The engagement protrusion 64 is disposed upward and frontward of the pressing protrusion 60 R. The engagement protrusion 64 extends rightward from the right surface of the side wall 53 R and has a generally rectangular cylindrical shape. The engagement protrusion 64 has an upper front end portion 64 A that has a wedge-like shape in a side view. The wedge-shaped upper front end portion 64 A has an apex portion that is directed upward and frontward in a side view.

The contact part 101 is disposed on a front end portion of the side wall 53 R. The contact part 101 extends rightward from the right surface of the side wall 53 R and has a U-shape whose rear end is open in a side view. The contact part 101 has a front surface that is curved such that a center portion thereof in the up-down direction projects forward. The contact part 101 is configured to be pressed rearward by a front cover 86 (described later) toward the photosensitive drum 4 when the process cartridge 1 is mounted on a main body 82 (see FIG. 16 ).

The lower wall 54 has a plate-like shape that extends in the front-rear direction. The lower wall 54 has a left end connected to a lower end of the side wall 53 L, and a right end connected to a lower end of the side wall 53 R.

The front wall 55 has a plate-like shape and is connected to a front end of the lower wall 54 to extend upward therefrom. The front wall 55 has a left end connected to a front end of the side wall 53 L, and a right end connected to a front end of the right wall 53 R. The front wall 55 includes a gripping part 76 and a plurality of protrusions 103 .

The gripping part 76 is disposed at a left-right center portion of the front wall 55 on a front end thereof. The gripping part 76 protrudes forward from the front end of the front wall 55 and has a rectangular frame-like shape in a plan view.

As illustrated in FIGS. 6 and 9 , the protrusions 103 protrude forward from the front end of the front wall 55 . Each protrusion 103 has a box-like shape and has an upper end portion in communication with the toner storage portion 10 . This upper end portion in communication with the toner storage portion 10 is a communication part 103 A, and has a length in the up-down direction shorter than a length of an inner space defined by the protrusion 103 in the up-down direction.

With this structure, toner flow from the toner storage portion 10 into the protrusion 103 can be suppressed. Further, even if toner flows into the protrusion 103 from the toner storage portion 10 , the toner within the protrusion 103 can be suppressed from flowing back into the toner storage portion 10 .

The upper wall 56 has a rectangular plate-like shape in a plan view. The upper wall 56 has a front end fixed to an upper end of the front wall 55 , a left end fixed to an upper end of the side wall 53 L, and a right end fixed to an upper end of the side wall 53 R.

(2) Drive Part

As illustrated in FIG. 5 , the drive part 52 is provided on a left end portion of the developing cartridge 3 at a position leftward of the developing frame 51 . The drive part 52 includes a gear train (not illustrated) including a plurality of gears, and a gear cover 66 covering the gear train.

As illustrated in FIGS. 7 and 11 , the gear cover 66 includes an opening 75 . The pressing protrusion 60 L is exposed through the opening 75 .

4. Detachment of the Developing Cartridge from the Drum Cartridge

(1) Developing Cartridge Attached to the Drum Cartridge

As illustrated in FIGS. 1 and 10 , the developing cartridge 3 can be attached to the developing cartridge attachment section 49 of the drum cartridge 2 . That is, when the developing cartridge 3 is attached to the drum cartridge 2 , the side wall 53 L of the developing cartridge 3 is disposed rightward of the side wall 24 L to oppose the same. Also, the side wall 53 R of the developing cartridge 3 is disposed leftward of the side wall 24 R to oppose the same.

When the developing cartridge 3 is attached to the drum cartridge 2 , the left end of the developing-roller shaft 7 A is fitted into (received in) the fitting part 30 C of the guide groove 29 L formed in the side wall 24 L. Likewise, the right end of the developing-roller shaft 7 A is fitted into (received in) the fitting part 31 C of the guide groove 29 R formed in the side wall 24 R. With this structure, the developing roller 7 is fixed in position relative to the photosensitive drum 4 in the up-down direction.

When the developing cartridge 3 is attached to the drum cartridge 2 , the front end portion of the developing cartridge 3 is positioned protrudes frontward relative to the front end portion of the drum cartridge 2 . The front end portion of the developing cartridge 3 is positioned between the front end portion of the side wall 24 L and the front end portion of the side wall 24 R of the drum cartridge 2 .

Further, as illustrated in FIGS. 1 and 2 , the lower end of the side wall 24 L and the lower end of the side wall 24 R of the developing cartridge 3 respectively contact the pair of rollers 28 of the drum cartridge 2 .

Further, as illustrated in FIG. 11 , the rear surface 40 of the pressing member 26 L contacts the front surface 61 of the pressing protrusion 60 L of the developing cartridge 3 and urges the pressing protrusion 60 L rearward by the urging force of the compression spring 39 L. Likewise, as illustrated in FIG. 12 , the rear surface 41 of the pressing member 26 R contacts the front surface 62 of the pressing protrusion 60 R of the developing cartridge 3 and urges the pressing protrusion 60 R rearward by the urging force of the compression spring 39 R. Accordingly, the developing cartridge 3 attached to the drum cartridge 2 is urged rearward, thereby enabling the developing roller 7 to be pressed against the photosensitive drum 4 .

At this time, the pressing member 26 L and the pressing member 26 R are respectively disposed between the rollers 28 and the developing roller 7 in the front-rear direction. Further, the pressing member 26 R is disposed between the photosensitive drum 4 and the locking member 27 in the front-rear direction. In other words, the pressing member 26 R and the photosensitive drum 4 define a distance therebetween that is shorter than a distance defined between the locking member 27 and the photosensitive drum 4 .

Further, referring to FIG. 11 , assuming that the pressing protrusion 60 L and the pressing protrusion 60 L are in contact with each other at a contact position C, the rotation axis A 1 of the photosensitive drum 4 and the contact position C define a distance L 1 therebetween that is shorter than a distance L 2 defined between the rotation axis A 1 of the photosensitive drum 4 and the rotation axis A 3 of the agitator shaft 11 A.

It should be noted that, since the pressing protrusion 60 L and the pressing protrusion 60 R are arranged to be in coincident with each other when viewed in the left-right direction, the rotation axis A 1 of the photosensitive drum 4 and a contact position at which the pressing protrusion 60 L and the pressing member 26 L contact each other also define a distance therebetween that is shorter than the distance L 2 between the rotation axis A 1 of the photosensitive drum 4 and the rotation axis A 3 of the agitator shaft 11 A.

Further, as illustrated in FIG. 10 , the locking member 27 is disposed between the side wall 53 R of the developing cartridge 3 and the side wall 24 R of the drum cartridge 2 .

As illustrated in FIG. 12 , the claw 43 A of the restricting part 43 of the locking member 27 is disposed on the upper front end 64 A of the engagement protrusion 64 of the developing cartridge 3 . That is, the claw 43 A is engaged with the engagement protrusion 64 . At this time, the lower rear end portion of the lifting part 45 is disposed below and frontward of the contact protrusion 63 .

The locking member 27 is at the restricting position and is positioned to be spaced away from the pressing member 26 R so as not to interfere with the pressing member 26 R.

(2) Detachment of the Developing Cartridge from Drum Cartridge

First, the operation part 44 of the locking member 27 is pressed forward and downward by a user in the state illustrated in FIG. 12 . The locking member 27 is caused to pivot counterclockwise about the shaft 42 in a right side view.

Then, as illustrated in FIG. 13 , the lifting part 45 contacts the contact protrusion 63 of the developing cartridge 3 from a lower-front side thereof.

As the operation part 44 of the locking member 27 is further pressed forward and downward by the user, the locking member 27 is further caused to pivot counterclockwise about the shaft 42 in a right side view.

The lifting part 45 thus presses the contact protrusion 63 of the developing cartridge 3 rearward and upward so that the right end portion of the developing cartridge 3 is lifted rearward and upward.

As a result, as illustrated in FIG. 14 , the right end portion of the developing cartridge 3 is caused to pivot clockwise about the rear end portion of the developing roller 7 in a right side view.

At this time, since only the right end portion of the developing cartridge 3 is lifted upward by the locking member 27 , the right end portion is caused to slightly deform relative to the left end portion such that the right end portion is twisted clockwise in a right side view relative to the left end portion.

As a result, an upper rear end portion E of the side wall 24 R of the developing cartridge 3 is brought into contact with the front surface 50 A of the contact part 50 of the cover frame 23 of the drum cartridge 2 . Accordingly, the cover frame 23 of the drum cartridge 2 can prevent the right end portion of the developing cartridge 3 from moving further rearward. At this time, the side wall 24 L of the developing cartridge 3 does not make contact with the cover frame 23 of the drum cartridge 2 .

When the operation part 44 of the locking member 27 is further pressed forward and downward by the user, the locking member 27 is caused to further pivot counterclockwise about the shaft 42 in a right side view.

The lifting part 45 thus further presses the contact protrusion 63 of the developing cartridge 3 upward so that the right end portion of the developing cartridge 3 is lifted further upward.

The right end portion of the developing cartridge 3 is therefore further caused to pivot clockwise about the upper rear end portion E of the side wall 24 R of the developing cartridge 3 in a right side view.

When the locking member 27 reaches the non-restricting position as illustrated in FIG. 15 , the pressing protrusion 60 R is disengaged upward from the pressing member 26 R. Subsequently, deformation of the developing cartridge 3 is restored, and the pressing protrusion 60 L is disengaged upward from the pressing member 26 L.

When the user lifts the developing cartridge 3 upward by gripping the gripping part 76 at this time, the developing cartridge 3 can be removed upward from the developing cartridge attachment section 49 of the drum cartridge 2 .

Detachment of the developing cartridge 3 from the drum cartridge 2 is thus complete.

For attaching the developing cartridge 3 to the drum cartridge 2 , the user grips the gripping part 76 , inserts the rear end portion of the developing cartridge 3 into the developing cartridge attachment section 49 of the drum cartridge 2 from above, and presses the front end portion of the developing cartridge 3 downward.

In the meantime, the developing roller 7 makes contact with the photosensitive drum 4 from its front side, and the developing cartridge 3 is then caused to pivot clockwise about the rear end thereof in a left side view. The developing cartridge 3 is thus received in and attached to the developing cartridge attachment section 49 .

Attachment of the developing cartridge 3 to the drum cartridge 2 is thus complete.

5. How the Process Cartridge is Used

As illustrated in FIG. 16 , the process cartridge 1 can be used when mounted in an image forming apparatus 81 .

The image forming apparatus 81 is an electro-photographic monochromatic printer. The image forming apparatus 81 includes the main body 82 , the process cartridge 1 , a scanner unit 83 , and a fixing unit 84 .

The main body 82 is formed in a box-like shape. The main body 82 includes an opening 85 , the front cover 86 , a sheet feed tray 87 , and a sheet discharge tray 88 .

The opening 85 is formed in a front end portion of the main body 82 . The opening 85 is formed to establish communication between the inside and the outside of the main body 82 in the front-rear direction. The process cartridge 1 can be mounted in and removed from the main body 82 through the opening 85 .

The front cover 86 is disposed on the front end portion of the main body 82 . The front cover 86 has a plate-like shape and extends in the up-down direction. The front cover 86 is supported by a front wall of the main body 82 such that the front cover 86 can pivot about a lower end thereof. The front cover 86 is configured to open and close the opening 85 .

The sheet feed tray 87 is disposed in a bottom portion of the main body 82 . The sheet feed tray 87 is configured to accommodate a stack of sheets P therein.

The sheet discharge tray 88 is formed on an upper wall of the main body 82 to occupy a front half of the same. The sheet discharge tray 88 is recessed downward from an upper surface of the upper wall of the main body 82 for receiving the sheets P thereon.

When mounted in the main body 82 , the process cartridge 1 is accommodated in a generally center portion of the main body 82 in the up-down direction. The process cartridge 1 is mounted in or removed from the main body 82 through the opening 85 .

The scanner unit 83 is disposed above the process cartridge 1 mounted in the main body 82 . The scanner unit 83 is configured to emit a laser beam toward the photosensitive drum 4 based on image data (see a broken line in FIG. 16 ).

The fixing unit 84 is disposed rearward of the process cartridge 1 mounted in the main body 82 . The fixing unit 84 includes a heat roller 89 and a pressure roller 90 in pressure contact with a lower rear portion of the heat roller 89 .

When an image forming operation is started in the image forming apparatus 81 , the scorotron charger 5 uniformly charges a surface of the photosensitive drum 4 . The scanner unit 83 exposes the surface of the photosensitive drum 4 . An electrostatic latent image is thus formed on the surface of the photosensitive drum 4 based on image data.

The agitator 11 then rotates about the agitator shaft 11 A (rotation axis A 3 ) for agitating the toner within the toner storage portion 10 and supplies the toner to the supply roller 8 . That is, the agitator 11 conveys the toner in a direction perpendicular to the rotation axis A 3 , i.e., frontward. The supply roller 8 then supplies the toner conveyed by the agitator 11 to the developing roller 7 . At this time, the toner is tribo-charged positively between the developing roller 7 and the supply roller 8 , and is carried on the developing roller 7 . The thickness regulation blade 9 regulates the toner carried on the developing roller 7 into a uniform thickness.

Then, the toner carried on the developing roller 7 is supplied to the electrostatic latent image on the surface of the photosensitive drum 4 to form a toner image on the surface of the photosensitive drum 4 .

The sheet P is fed, one by one, from the sheet feed tray 87 to a position between the photosensitive drum 4 and the transfer roller 6 at a predetermined timing by rotations of various rollers. The toner image on the surface of the photosensitive drum 4 is transferred onto the sheet P when the sheet P passes between the photosensitive drum 4 and the transfer roller 6 .

Subsequently, the sheet P is applied with heat and pressure when passing between the heat roller 89 and the pressure roller 90 . The toner image on the sheet P is thus thermally fixed onto the sheet P. The sheet P is finally discharged onto the sheet discharge tray 88 .

6. Operational and Technical Advantages

(1) According to the process cartridge 1 and the drum cartridge 2 of the embodiment, as illustrated in FIG. 2 , the pressing member 26 R is positioned closer to the photosensitive drum 4 than the locking member 27 is to the photosensitive drum 4 in the front-rear direction. That is, the pressing member 26 R is arranged between the locking member 27 and the photosensitive drum 4 . Further, the distance between the pressing member 26 L and the photosensitive drum 4 is equal to the distance between the pressing member 26 R and the photosensitive drum 4 .

In other words, the distance (shortest distance) between “the contact position C at which the pressing member 26 L of the drum cartridge 2 and the pressing protrusion 60 L of the developing cartridge 3 are in contact with each other” and “the rotation axis A 1 of the photosensitive drum 4 ” (or, the distance L 1 ) is shorter than a distance (shortest distance) between “a position at which the locking member 27 of the drum cartridge 2 and the engagement protrusion 64 of the developing cartridge 3 engage each other” and “the rotation axis A 1 of the photosensitive drum 4 ”. Further, the distance (shortest distance) between “the contact position at which the pressing protrusion 60 R of the developing cartridge 3 and the pressing member 26 R of the drum cartridge 2 are in contact with each other” and “the rotation axis A 1 of the photosensitive drum 4 ” is shorter than the distance (shortest distance) between “the position at which the locking member 27 of the drum cartridge 2 and the engagement protrusion 64 of the developing cartridge 3 engage each other” and “the rotation axis A 1 of the photosensitive drum 4 ”.

Accordingly, even if front end portions of the side wall 24 L and the side wall 24 R are not connected to each other, that is, even if the drum cartridge 2 is not provided with a front wall, the developing cartridge 3 can be stably pressed toward the photosensitive drum 4 by the pressing member 26 L and the pressing member 26 R that are positioned closer to the photosensitive drum 4 than the locking member 27 is to the photosensitive drum 4 .

Thus, even if the size of the developing cartridge 3 is made larger in a frontward direction (in a direction away from the photosensitive drum 4 ) in order to increase the amount of toner to be stored in the toner storage portion 10 , the developing roller 7 can be stably pressed against the photosensitive drum 4 .

Further, a space frontward of the pressing member 26 R can be efficiently utilized for arranging the locking member 27 .

(2) According to the process cartridge 1 and the drum cartridge 2 of the embodiment, as illustrated in FIG. 11 , the distance L 1 between the contact position C (at which the pressing member 26 L and pressing protrusion 60 L are in contact with each other) and the rotation axis A 1 of the photosensitive drum 4 is shorter than the distance L 2 between the rotation axis A 3 of the agitator 11 and the rotation axis A 1 of the photosensitive drum 4 .

That is, the developing cartridge 3 (pressing protrusion 60 L) can be pressed toward the photosensitive drum 4 at a position closer to the photosensitive drum 4 than the agitator shaft 11 A is to the photosensitive drum 4 .

As a result, the developing roller 7 can be more stably pressed against the photosensitive drum 4 .

(3) According to the process cartridge 1 and the drum cartridge 2 of the embodiment, as illustrated in FIGS. 13 and 14 , the pressing member 26 L and the pressing member 26 R can move linearly in the front-rear direction (toward and away from the photosensitive drum 4 ).

Hence, the developing cartridge 3 can be reliably pressed toward the photosensitive drum 4 . As a result, the developing roller 7 can be more stably pressed against the photosensitive drum 4 .

(4) In the process cartridge 1 and the drum cartridge 2 of the embodiment, as illustrated in FIG. 6 , the pressing protrusion 60 R protrudes rightward from the side wall 53 R. Thus, the pressing protrusion 60 R can be easily accessed from its right side.

Further, as illustrated in FIG. 8 , the pressing protrusion 60 L protrudes leftward from the side wall 53 L.

Thus, the pressing protrusion 60 L can be easily accessed from its left side.

(5) In the process cartridge 1 and the drum cartridge 2 according to the embodiment, as illustrated in FIG. 6 , the engagement protrusion 64 configured to engage the locking member 27 protrudes rightward from the side wall 53 R.

Hence, the locking member 27 can be easily brought into engagement with the engagement protrusion 64 from the right side.

(6) In the process cartridge 1 and the drum cartridge 2 of the embodiment, as illustrated in FIGS. 2 and 3 , the locking member 27 can be reliably maintained at the restricting position by the urging force of the tension spring 47 .

Hence, the developing cartridge 3 can be reliably restricted from getting detached from the drum cartridge 2 .

(7) According to the process cartridge 1 and the drum cartridge 2 , as illustrated in FIG. 10 , the locking member 27 is disposed between the side wall 53 R of the developing frame 51 and the side wall 24 R of the drum frame 21 .

The locking member 27 can be reliably arranged in a space available between the side wall 53 R of the developing frame 51 and the side wall 24 R of the drum frame 21 .

(8) According to the process cartridge 1 and the drum cartridge 2 of the embodiment, as illustrated in FIG. 2 , the locking member 27 is disposed between the wall portion 35 and the side wall 24 R of the drum frame 21 .

Hence, the locking member 27 can be reliably supported so as to be sandwiched between the wall portion 35 and the side wall 24 R of the drum frame 21 .

(9) According to the process cartridge 1 and the drum cartridge 2 of the embodiment, as illustrated in FIGS. 1 and 2 , the locking member 27 is disposed between the developing roller 7 and the rollers 28 with which the developing cartridge 3 is brought into contact from above.

Hence, as illustrated in FIG. 11 , the pressing member 26 L and the pressing member 26 R can press the developing cartridge 3 toward the photosensitive drum 4 , while positioning of the developing cartridge 3 relative to the drum cartridge 2 in the up-down direction can be realized by bringing the developing cartridge 3 into abutment contact with the rollers 28 .

The developing cartridge 3 can therefore be more reliably pressed toward the photosensitive drum 4 .

Further, at this time, as shown in FIG. 12 , the locking member 27 can reliably restrict detachment of the developing cartridge 3 from the drum cartridge 2 .

(10) According to the process cartridge 1 and the drum cartridge 2 of the embodiment, as illustrated in FIG. 4 , the pressing member 26 L is disposed between the left roller 28 and the photosensitive drum 4 . The pressing member 26 R is disposed between the right roller 28 and the photosensitive drum 4 .

The rollers 28 can be brought into contact with the developing cartridge 3 at positions farther away from the developing roller 7 than the pressing member 26 L and the pressing member 26 R are from the developing roller 7 .

With this structure, positioning of the developing cartridge 3 in the up-down direction can be realized at a position farther away from the developing roller 7 than otherwise.

As a result, the developing cartridge 3 can be more stably pressed toward the photosensitive drum 4 .

(11) In the process cartridge 1 and the drum cartridge 2 of the embodiment, as illustrated in FIG. 2 , the rollers 28 are disposed on the front end portion of the drum cartridge 2 .

The rollers 28 can be brought into contact with the developing cartridge 3 at positions farthest away from the developing roller 7 .

As a result, the developing cartridge 3 can be more stably pressed toward the photosensitive drum 4 .

(12) In the process cartridge 1 and the drum cartridge 2 of the embodiment, as illustrated in FIG. 1 , the front wall 55 of the developing frame 51 is positioned beyond the drum frame 21 in the front-rear direction to be positioned frontward of the drum frame 21 .

The developing cartridge 3 can be made lager in size such that the front end portion of the developing cartridge 3 can enlarged frontward to extend beyond the drum frame 21 .

7. Variations and Modifications

(1) In the above-described embodiment, only one agitator 11 is provided inside the toner storage portion 10 . However, if the capacity of the toner storage portion 10 is to be increased, a plurality of the agitators 11 may be provided inside the toner storage portion 10 .

In this case, the distance L 1 between the contact position C (at which the pressing protrusion 60 L and the pressing member 26 L are in contact with each other) and the rotation axis A 1 of the photosensitive drum 4 may be shorter than a distance defined between the rotation axis A 3 of one of the agitators 11 positioned closest to the photosensitive drum 4 and the rotation axis A 1 of the photosensitive drum 4 .

According to the structure of this modification, the pressing member 26 L and pressing member 26 R can press the developing cartridge 3 at positions closer to the photosensitive drum 4 than the agitator shaft 11 A of the agitator 11 positioned closest to the photosensitive drum 4 among the plurality of agitators 11 is to the photosensitive drum 4 .

As a result, the developing roller 7 can be more stably pressed against the photosensitive drum 4 .

(2) In the depicted embodiment, the developing cartridge 3 is mounted in and removed from the main body 82 of the image forming apparatus 81 in a state where the developing cartridge 3 is attached to the drum cartridge 2 . However, alternatively, the developing cartridge 3 may be configured to be attached to and detached from the drum cartridge 2 that has already been mounted in the main body 82 of the image forming apparatus 81 .

(3) In the above-described embodiment, the rollers 28 serve as an example of a contact part. However, instead of the rollers 28 , a spherical protrusion protruding upward from the lower wall 25 of the drum cartridge 2 may serve as the contact part.

(4) Further, instead of the tension spring 47 , a rubber band, for example, may be used as an example of an urging member.

While the description has been made in detail with reference to specific embodiments thereof, it would be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the above described embodiments.