1. A method for manufacturing a reinforced thermoplastic structure, comprising:
providing a plurality of reinforcing filaments;
wetting the reinforcing filaments with a first thermoplastic resin;
introducing the reinforcing filaments with the first thermoplastic resin into a first portion of a die and maintaining said thermoplastic resin at a first temperature;
introducing a second thermoplastic resin into a second portion of the die;
contacting the second thermoplastic resin with the reinforcing filaments and the first thermoplastic resin within the second portion of said die; and
heating the first and second thermoplastic polymer resins to a second temperature to form a partially solidified reinforced thermoplastic structure having a predetermined outer shape; and
wherein the first temperature is a value below the solidification temperature of the first thermoplastic resin and the second temperature is a value above the solidification temperature of at least the first thermoplastic resin.
2. The method of claim 1, further comprising contacting the partially solidified reinforced thermoplastic structure with a third thermoplastic resin to form a capping layer on an exterior surface of the reinforced thermoplastic structure.
3. The method of claim 1, wherein the predetermined outer shape comprises a preshape form, the method further comprising directing the partially solidified reinforced thermoplastic structure through a sizing die or calibrator to impart a final form to the structure.
4-6. (canceled)
7. The method of claim 1, wherein the step of introducing said reinforcing filaments with the first thermoplastic resin into the first portion of a die further comprises providing the die with a filament channel sized and configured to receive the reinforcing filaments with the first thermoplastic resin, the filament channel further configured to direct the filaments to an introduction location of the second thermoplastic polymer within the die.
8. The method of claim 7, further comprising the step of maintaining a temperature of an interior surface of the filament channel below the solidification temperature of the first polymer while the first polymer is located within the filament channel.
9. The method of claim 8, wherein the filament channel has a proximal input end and a distal output end, and the distal output end is located adjacent to, or within, the second portion of the die, the distal output end being positioned to place the associated filaments at a predetermined cross-sectional location within the reinforced thermoplastic structure.
10-11. (canceled)
12. The method of claim 7, further comprising providing a plurality of filament channels, the plurality of filament channels being positioned within the die to place the reinforcing filaments at predetermined locations adjacent the second portion of the die to produce a reinforced thermoplastic structure having a predetermined reinforcement scheme.
13. (canceled)
14. The method of claim 1, wherein the second thermoplastic resin is introduced into the second portion of the die in a first flow direction, the first flow direction forming a first angle with respect to a movement direction of the reinforcing filament and the first thermoplastic resin through the die, and wherein the first angle is less than 90 degrees so that a component of the first flow direction is parallel to the movement direction.
15-17. (canceled)
18. The method of claim 2, wherein the first thermoplastic resin comprises plastisol, and the second thermoplastic resin comprises polyvinylchloride which is introduced into the second portion of the die at melt state.
19. The method of claim 2, wherein the third thermoplastic resin comprises an acrylic material which is introduced into the third portion of the die at melt state.
20. (canceled)
21. The method of claim 1, further comprising using a first extruder to melt the second thermoplastic resin, and providing a quantity of reinforcing material into the first extruder with the second thermoplastic resin.
22. The method of claim 1, wherein the first temperature is in the range of about 70-degrees Fahrenheit (F.) to about 250-degrees F. and the second temperature is in the range of 300-degrees F. to about 380-degrees F.
23. (canceled)
24. The method of claim 1, wherein the reinforcing filaments comprise a filament bundle.
25. The method of claim 1, further comprising introducing the partially solidified reinforced thermoplastic structure into a mold cavity and forming a final form to the structure within the mold.
26. (canceled)
27. A method for manufacturing a reinforced thermoplastic structure, comprising:
providing a reinforcing filament;
wetting the reinforcing filament with a first thermoplastic resin;
introducing the reinforcing filament with the first thermoplastic resin into a first portion of a die and maintaining said thermoplastic resin at a first temperature;
introducing a second thermoplastic resin into a second portion of the die;
contacting the second thermoplastic resin with the reinforcing filament wetted by the first thermoplastic resin within the second portion of said die;
transporting the first and second thermoplastic polymer resins through the second portion of said die while forming the first and second thermoplastic polymer resins into a reinforced thermoplastic structure having a predetermined outer shape; and
exposing the reinforced thermoplastic structure to a zone having a second temperature;
wherein the first temperature is a temperature at which the first thermoplastic resin is in a stable liquid state and the second temperature is a value at which the first thermoplastic resin can at least partially solidify.
28. The method of claim 27, further comprising contacting the at least partially solidified reinforced thermoplastic structure with a third thermoplastic resin to form a capping layer on an exterior surface of the reinforced thermoplastic structure.
29. The method of claim 27, wherein the predetermined outer shape comprises a preshape form, the method further comprising directing the partially solidified reinforced thermoplastic structure through a sizing die or calibrator to impart a final form to the structure.
30-32. (canceled)
33. The method of claim 27, wherein the step of introducing said reinforcing filament with the first thermoplastic resin into a first portion of a die further comprises providing the die with a filament channel sized and configured to receive the reinforcing filament with the first thermoplastic resin, the filament channel further configured to direct the filament to an introduction location of the second thermoplastic polymer within the die.
34. The method of claim 33, further comprising the step of maintaining a temperature of an interior surface of the filament channel below an upper solidification temperature of the first polymer while the first polymer is located within the filament channel.
35. The method of claim 33, wherein the filament channel has a proximal input end and a distal output end, and the distal output end is located adjacent to the introduction location of the second thermoplastic resin within the die, the distal output end being positioned to place the associated filaments at a predetermined cross-sectional location within the reinforced thermoplastic structure.
36-37. (canceled)
38. The method of claim 33, further comprising providing a plurality of reinforcing filaments associated with a corresponding plurality of filament channels, the plurality of corresponding filament channels being positioned within the die to place the reinforcing filaments at predetermined locations adjacent the second portion of the die so that the reinforced thermoplastic structure has a predetermined reinforcement scheme.
39. (canceled)
40. The method of claim 27, wherein the second thermoplastic resin is introduced into the second portion of the die in a first flow direction, the first flow direction forming a first angle with respect to a movement direction of the reinforcing filament and the first thermoplastic resin through the die, and wherein the first angle is less than 90 degrees so that a component of the first flow direction is parallel to the movement direction.
41-42. (canceled)
43. The method of claim 27, wherein the first thermoplastic resin is selected from the group consisting of plastisols and molten polymers.
44. The method of claim 28, wherein the first thermoplastic resin comprises plastisol, and the second thermoplastic resin comprises polyvinylchloride which is introduced into the second portion of the die at melt state.
45. The method of claim 44, wherein the third thermoplastic resin comprises an acrylic material which is introduced into a third portion of the die at melt state.
46-50. (canceled)
51. The method of claim 27, further comprising introducing the reinforced thermoplastic structure into a mold cavity and forming a final form to the structure within the mold.
52. (canceled)
53. The method of claim 27, wherein the stable liquid state of the first thermoplastic resin is selected from the group consisting of a polymer melt above a melting temperature, and a plastisol dispersion below a gelation point for the plastisol.
54. A method for manufacturing a reinforced thermoplastic structure, comprising:
providing a plurality of reinforcing filaments;
wetting the reinforcing filaments with a first thermoplastic resin;
introducing the reinforcing filaments with the first thermoplastic resin into a first portion of a die and maintaining said thermoplastic resin at a first temperature;
introducing a second thermoplastic resin into a second portion of the die;
contacting the second thermoplastic resin with the reinforcing filaments and the first thermoplastic resin within the second portion of said die;
heating the first and second thermoplastic polymer resins to a second temperature to form an at least partially solidified reinforced thermoplastic structure having a predetermined outer shape; and
contacting the reinforced thermoplastic structure with a third thermoplastic resin to form a capping layer on an exterior surface of the reinforced thermoplastic structure;
wherein the first temperature is a value below the solidification temperature of the first thermoplastic resin and the second temperature is a value above the solidification temperature of the first thermoplastic resin.
55. A method for manufacturing a reinforced thermoplastic structure, comprising:
providing a plurality of reinforcing filaments;
wetting the reinforcing filaments with a first thermoplastic resin at a first temperature, said first temperature corresponding to a substantially liquid state of said first thermoplastic resin;
introducing the reinforcing filaments with the first thermoplastic resin into a first portion of a die;
introducing a second thermoplastic resin into a second portion of the die;
contacting the second thermoplastic resin with the reinforcing filaments and the first thermoplastic resin within the second portion of said die; and
cooling the first and second thermoplastic polymer resins to a second temperature to form a partially solidified reinforced thermoplastic structure having a predetermined outer shape;
wherein the second temperature is a value below the solidification temperature of at least one of the first and second thermoplastic resins.
56. The method of claim 55, wherein the first thermoplastic resin comprises a high melt index acid containing polyolefin copolymer.
57. The method of claim 56, wherein the first thermoplastic resin is selected from the group consisting of acrylic acid copolymer, methacrylic acid copolymer, ethylene methacrylic acid copolymer, ethylene acrylic acid copolymer, butylene acrylic acid copolymer, butylene methacrylic acid copolymer, maleic acid modified ethylene copolymer, maleic acid modified propylene copolymer, ionomers of ethylene acrylic acid, ionomers of ethylene methacrylic acid, and mixtures and combinations thereof.
58. The method of claim 55, further comprising contacting the at least partially solidified reinforced thermoplastic structure with a third thermoplastic resin to form a capping layer on an exterior surface of the reinforced thermoplastic structure.
59. The method of claim 55, further comprising directing the partially solidified reinforced thermoplastic structure through a sizing die or calibrator to impart a final form to the structure.
60. (canceled)
61. The method of claim 55, wherein the step of introducing said reinforcing filaments with the first thermoplastic resin into a first portion of a die further comprises providing the die with at least one filament channel sized and configured to receive the reinforcing filaments with the first thermoplastic resin, the at least one filament channel further configured to direct the filaments to an introduction location of the second thermoplastic polymer within the die.
62. The method of claim 61, further comprising the step of maintaining a temperature of an interior surface of the at least one filament channel above a solidification temperature of the first thermoplastic resin while the first thermoplastic resin is located within the at least one filament channel.
63. The method of claim 62, wherein the at least one filament channel has a proximal input end and a distal output end, and the distal output end is located adjacent to the introduction location of the second thermoplastic resin within the die, the distal output end being positioned to place the associated filaments at a predetermined cross-sectional location within the reinforced thermoplastic structure.
64-65. (canceled)
66. The method of claim 61, further comprising providing a plurality of reinforcing filaments associated with a corresponding plurality of filament channels, the plurality of corresponding filament channels being positioned within the die to place the reinforcing filaments at predetermined locations adjacent the second portion of the die so that the reinforced thermoplastic structure has a predetermined reinforcement scheme.
67-70. (canceled)
71. The method of claim 55, further comprising introducing the reinforced thermoplastic structure into a mold cavity and forming a final form to the structure within the mold.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A developing device having stirring members for stirring a developer-tank-contained developer containing toner and carrier while conveying the developer along conveying passages inside a developer tank and a developer holder disposed adjacent to said stirring members to supply the stirred developer-tank-contained developer to an electrostatic latent image holder, comprising:
a developer replenishing tank for replenishing a replenishment developer containing toner and carrier to said developer tank, and
a discharging mechanism for discharging an excessive amount of the developer-tank-contained developer outside said developer tank from a discharge opening section when the amount of the developer-tank-contained developer to be conveyed using said stirring members inside said developer tank exceeds a predetermined full filling amount, wherein
the initial filling amount of the developer-tank-contained developer to be filled initially into said developer tank is set so as to be less than said full filling amount.
2. The developing device according to claim 1, wherein the amount of the carrier initially contained in the developer-tank-contained developer is less than the amount of the carrier contained in the developer-tank-contained developer at the time of full filling.
3. The developing device according to claim 1, wherein said initial filling amount is larger than an amount just prior to the limit filling amount at which improper image formation occurs because of the shortage of the developer-tank-contained developer.
4. The developing device according to claim 1, wherein the ratio of the carrier contained in the replenishment developer that is filled first time into said developer replenishing tank is set so as to be lower than the ratio of the carrier contained in the replenishment developer that is filled after the first time.
5. The developing device according to claim 1, wherein said developer replenishing tank is configured so as to be attachable and detachable to and from said developing device and is equipped with an information storage medium that stores information regarding the ratio of the carrier contained in the replenishment developer filled in said developer replenishing tank.
6. An image forming apparatus comprising:
a rotatable electrostatic latent image holder for holding electrostatic latent images on the circumferential face thereof,
a developing device having stirring members for stirring a developer-tank-contained developer containing toner and carrier while conveying the developer along conveying passages inside a developer tank and a developer holder disposed adjacent to said stirring members to supply the stirred developer-tank-contained developer to said electrostatic latent image holder, said image forming apparatus further comprising:
a developer replenishing tank for replenishing a replenishment developer containing toner and carrier to said developer tank, and
a discharging mechanism for discharging an excessive amount of the developer-tank-contained developer outside said developer tank from a discharge opening section when the amount of the developer-tank-contained developer to be conveyed using said stirring members inside said developer tank exceeds a predetermined full filling amount, wherein
the initial filling amount of the developer-tank-contained developer to be filled initially into said developer tank is set so as to be less than said full filling amount.
7. The image forming apparatus according to claim 6, wherein the amount of the carrier initially contained in the developer-tank-contained developer is less than the amount of the carrier contained in the developer-tank-contained developer at the time of full filling.
8. The image forming apparatus according to claim 6, wherein said initial filling amount is larger than an amount just prior to the limit filling amount at which improper image formation occurs because of the shortage of the developer-tank-contained developer.
9. The image forming apparatus according to claim 6, wherein the ratio of the carrier contained in the replenishment developer that is filled first time into said developer replenishing tank is set so as to be lower than the ratio of the carrier contained in the replenishment developer that is filled after the first time.
10. The image forming apparatus according to claim 6, wherein said developer replenishing tank is configured so as to be attachable and detachable to and from said developing device and is equipped with an information storage medium that stores information regarding the ratio of the carrier contained in the replenishment developer filled in said developer replenishing tank.
11. A method for filling developer into the developer tank of a developing device comprising stirring members for stirring a developer-tank-contained developer containing toner and carrier while conveying the developer along conveying passages inside a developer tank, a developer holder disposed adjacent to said stirring members to supply the stirred developer-tank-contained developer to an electrostatic latent image holder, a developer replenishing tank for replenishing a replenishment developer containing toner and carrier to said developer tank, and a discharging mechanism for discharging an excessive amount of the developer-tank-contained developer outside said developer tank from a discharge opening section when the amount of the developer-tank-contained developer to be conveyed using said stirring members inside said developer tank exceeds a predetermined full filling amount, wherein
the initial filling amount of the developer-tank-contained developer to be filled initially into said developer tank is set so as to be less than said full filling amount.