Exemplary embodiments of the present invention are described in detail below with reference to the accompanying drawings.
Description of an image forming apparatus that includes a belt-rotating mechanism and an attach-detach mechanism for transfer units is given below.
The toner-image forming unit 1a includes a photosensitive drum 2a, a drum charger 3a, a light exposing unit 4a, a toner-image developer 5a, a primary transfer unit 6a, and a drum-cleaning unit 7a. The remaining toner-image forming units 1b to 1d also have an identical structure to that of the toner-image forming unit 1a. The description of the toner-image forming units 1b to 1d is omitted to avoid redundant explanation. Components in the toner-image forming units 1b to 1d identical to those in the toner-image forming unit 1a have same reference numerals except corresponding letters ‘b’, ‘c’, and ‘d’ replacing the letter ‘a’.
Each of the toner-image forming units 1a, 1b, 1c, and 1d forms a toner image in a single color of yellow, magenta, cyan, and black. When the toner-image forming unit 1a receives an instruction from a controller (not shown) to start an image forming process, the photosensitive drum 2a starts rotating in the direction shown by an arrow mark ‘G’ (anticlockwise direction). When the photosensitive drum 2a starts rotating, a high voltage is applied to the drum charger 3a that in turn electrically charges the surface of the photosensitive drum 2a in a uniform manner with a negative voltage.
The controller then sends, in the form of ON/OFF signals from the light exposing unit 4a, character data or graphic data converted in a dot image to the toner-image forming unit 1a. After the toner-image forming unit 1a receives the dot image, the surface of the photosensitive drum 2a is selectively exposed to light based on the dot image by using laser beams emitted from the light exposing unit 4a. As a result, the voltage at portions exposed to light decreases thereby forming an electrostatic latent image. When the electrostatic latent image on the photosensitive drum 2a reaches a position facing the toner-image developer 5a, the toner-image developer 5a blows a negatively charged yellow toner onto the electrostatic latent image so that the electrostatic latent image is converted into a yellow toner image.
The yellow toner image formed on the photosensitive drum 2a reaches the primary transfer unit 6a. The intermediate transfer belt 10, which rotates in the direction shown by an arrow mark ‘A’ (clockwise direction), is sandwiched between the photosensitive drum 2a and the primary transfer unit 6a. The primary transfer unit 6a is at a voltage higher than that of the photosensitive drum 2a because of which the yellow toner image is transferred onto the intermediate transfer belt 10, which is sandwiched between the photosensitive drum 2a and the primary transfer unit 6a. After the yellow toner image is transferred onto the intermediate transfer belt 10, the drum-cleaning unit 7a scrapes out any residual toner from the surface of the photosensitive drum 2a. Thus, the photosensitive drum 2a is kept ready to receive next dot-image data and repeat the image forming process for the next dot-image data.
In the same manner as the toner-image forming unit 1a forms a yellow toner image on the photosensitive drum 2a, the toner-image forming unit 1b forms a magenta toner image on the photosensitive drum 2b. Because of the action of the primary transfer unit 6b the magenta toner image is transferred onto the intermediate transfer belt 10. The timing of transferring the magenta toner image onto the intermediate transfer belt 10 is adjusted to match with the timing at which the yellow toner image, which is present on the photosensitive drum 2a, reaches the primary transfer unit 6b. The timing is so adjusted that the yellow toner image and the magenta toner image are superimposed onto each other over the intermediate transfer belt 10.
In the same manner, the toner-image forming unit 1c forms a cyan toner image on the photosensitive drum 2c, and the toner-image forming unit 1d forms a black toner image on the photosensitive drum 2d. The cyan toner image and the black toner image are also superimposed onto the image present on the intermediate transfer belt 10 thereby forming a full-color toner image in.
The full-color toner image then reaches a secondary transfer unit 9 as the intermediate transfer belt 10 rotates. At the same time, a recording paper 8 that is conveyed from a paper feeding unit (not shown) in the direction shown by an arrow mark ‘H’ also reaches the secondary transfer unit 9. The recording paper 8 is sandwiched between the intermediate transfer belt 10 and the secondary transfer unit 9. The secondary transfer unit 9 is at a voltage higher than that of the intermediate transfer belt 10 because of which the full-color toner image is transferred onto the recording paper 8, which is sandwiched between the intermediate transfer belt 10 and the secondary transfer unit 9. The recording paper 8 with the full-color toner image is then conveyed to a fixing unit 11 where the full-color toner image is fixed on the recording paper 8 by using heat and/or pressure. After the toner image in full color is transferred onto the recording paper 8, a belt-cleaning unit 12 scrapes out any residual toner on the intermediate transfer belt 10.
Given below is the description of the attach-detach mechanism for transfer units. The attach-detach mechanism includes a first attach-detach device 13, a second attach-detach device 14, and a third attach-detach device 15. The first attach-detach device 13 lifts the primary transfer units 6a to 6c, which are used for primary-transferring the toner images in yellow, cyan, and magenta, respectively, so that the intermediate transfer belt 10 is abutted against the photosensitive drums 2a to 2c. On the other hand, the first attach-detach device 13 lowers the primary transfer units 6a to 6c so that the intermediate transfer belt 10 is detached from the photosensitive drums 2a to 2c.
As shown in
Similarly, the second attach-detach device 14 lifts the primary transfer unit 6d, which is used for primary-transferring the black toner image, so that the intermediate transfer belt 10 is abutted against the photosensitive drum 2d, and lowers the primary transfer unit 6d so that the intermediate transfer belt 10 is detached from the photosensitive drum 2d. The third attach-detach device 15 lifts the secondary transfer unit 9, which is used for secondary-transferring the toner image in full color, so that the intermediate transfer belt 10 is abutted against the secondary transfer unit 9, and lowers the secondary transfer unit 9 so that the secondary transfer unit 9 is detached from the intermediate transfer belt 10. Similar to the first attach-detach device 13, the second attach-detach device 14 and the third attach-detach device 15 make the intermediate transfer belt 10 abut against the photosensitive drum 2d and the secondary transfer unit 9, respectively, before starting the image forming process, while detach the intermediate transfer belt 10 from the photosensitive drum 2d and the secondary transfer unit 9, respectively, after completing the image forming process.
Given below is the description of the belt-rotating mechanism.
The belt-rotating mechanism includes a driving roller 16, four driven rollers 17a to 17d, a steering roller 18, and a belt-rotating motor 19. The intermediate transfer belt 10 is stretched around the driving roller 16, the driven rollers 17a to 17d, and the steering roller 18. The driving roller 16 is coupled with the belt-rotating motor 19. The belt-rotating motor 19 rotates the driving roller 16 that in turn rotates the intermediate transfer belt 10 in the clockwise direction.
Sometimes the four toner images for yellow, magenta, cyan, and black that are formed by the toner-image forming units 1a, 1b, 1c, and 1d, respectively, are misaligned with respect to each other in the direction along the width of the intermediate transfer belt 10. The degree of relative misalignment is maximum in case of the toner images formed in the toner-image forming unit 1a and the toner-image forming unit 1d, which are arranged farthest from each other. It is recommended to curb the relative misalignment of two toner images within 48 micrometers in the direction along the width of the intermediate transfer belt 10.
There are various factors that cause the misalignment of the toner images on the intermediate transfer belt 10. One of them is meandering of the intermediate transfer belt 10. To minimize the misalignment of the toner images, it is necessary to curb the misaligning within 33 micrometers in the direction along the width of the intermediate transfer belt 10 when the intermediate transfer belt 10 reaches each of the toner-image forming units 1a to 1d. To achieve that, it is necessary to constantly curb the meandering speed of the rotating intermediate transfer belt 10 within the allowed range. The allowed range for the meandering speed for the intermediate transfer belt 10 is, for example, ±19.5 μm/s.
To correct over-meandering of the intermediate transfer belt 10, as shown in
When the off-center cam 24 pivots in the direction shown by letter D in
When the side surface of the steering roller 18 tilts in the direction shown by letter F, the tension at the front side of the intermediate transfer belt 10 becomes larger as compared to the tension at the rear side. As a result, the intermediate transfer belt 10 meanders towards the rear side at a meandering speed that depends on the tilt angle of the steering roller 18, which is formed when the steering roller 18 tilts in the direction shown by letter F. On the other hand, when the off-center cam 24 pivots in the direction shown by letter D′ in
When the side surface of the steering roller 18 tilts in the direction shown by letter F′, the tension at the rear side of the intermediate transfer belt 10 increases as compared to that at the front side. As a result, the intermediate transfer belt 10 meanders towards the front side at a meandering speed that depends on the tilt angle of the steering roller 18, which is formed when the steering roller 18 tilts in the direction shown by letter F′.
In this manner, when the intermediate transfer belt 10 meanders towards the front side, the steering roller 18 is made to tilt at such an angle that the intermediate transfer belt shifts back towards the rear side. On the other hand, when the intermediate transfer belt 10 meanders towards the rear side, the steering roller 18 is made to tilt at such an angle that the intermediate transfer belt shifts back towards the front side. Thus, meandering of the intermediate transfer belt 10 is controlled by adjusting the tilt movement and the tilt angle of the steering roller 18 thereby curbing the meandering speed of the intermediate transfer belt 10 within the allowed range.
Given below is a description with reference to
The displacement sensor 31 is arranged near between a center and an end of the first contact plate 30a. The displacement sensor 31 includes a light emitting unit (not shown) and a light receiving unit (not shown). The light emitted by the light emitting unit is reflected by the first contact plate 30a. The light receiving unit receives the reflected light. The displacement sensor 31 detects the distance up to the first contact plate 30a by comparing the position of the reflected light with a reference position.
The displacement sensor 31 is arranged at a predetermined distance, e.g. 6.5 millimeters, from the first contact plate 30a. The distance between the displacement sensor 31 and the first contact plate 30a varies when the contact member 30 pivots upon the contact-member shaft 32. The displacement sensor 31 outputs an electrical signal indicative of the distance between the displacement sensor 31 and the first contact plate 30a.
The belt-rotating mechanism implements a steering method to control meandering of the intermediate transfer belt 10. More particularly, meandering of the intermediate transfer belt 10 is controlled by adjusting the tilt angle of the steering roller 18 thereby retaining a uniform tension in the direction along the width of the intermediate transfer belt 10. To control meandering of the intermediate transfer belt 10, implementing the steering method is a better option than guiding the edges of the intermediate transfer belt 10. That is because implementing the steering method saves the intermediate transfer belt 10 from over-burdening thereby enhancing its durability. However, any sudden addition of an uneven tension in the direction along the width of the intermediate transfer belt 10 that is under rotation still results in meandering of the intermediate transfer belt 10. In that case, the meandering speed may exceed the allowed range during a period required for the intermediate transfer belt 10 to resume stable rotation.
Moreover, in the attach-detach mechanism, the process of abutting or detaching produces jolts of varying degrees depending on each attach-detach device, which may result in sudden addition of an uneven tension in the direction along the width of the intermediate transfer belt 10 that is under rotation. More particularly, when the first attach-detach device 13 and the second attach-detach device 14 lift the intermediate transfer belt 10, the tension in the direction along the width of the intermediate transfer belt 10 that develops on each roller supporting it varies. Furthermore, nip pressure in the direction along the width of the intermediate transfer belt 10 also varies depending on whether the intermediate transfer belt 10 is abutted against or detached from the photosensitive drums 2a to 2d and the secondary transfer unit 9.
Thus, during the image forming process, if the photosensitive drums 2a to 2d and the secondary transfer unit 9 are abutted against or detached from the rotating intermediate transfer belt 10, there is a high possibility that the meandering speed of the intermediate transfer belt 10 exceeds the allowed range because of the variation in tension in the direction along its width. Hence, to control the meandering speed, it is recommended to rotate the intermediate transfer belt 10 only when it is abutted against the photosensitive drums 2a to 2d and the secondary transfer unit 9. In other words, when starting or stopping the rotation of the intermediate transfer belt 10, it is necessary to consider whether the photosensitive drums 2a to 2d and the secondary transfer unit 9 are in the abutted state or detached state, so that the period for which the intermediate transfer belt 10 rotates without being abutted against the photosensitive drums 2a to 2d and the secondary transfer unit 9 can be minimized.
It is obvious that a certain amount of time is required to curb the meandering speed of the intermediate transfer belt 10. Unless the meandering speed of the intermediate transfer belt 10 is curbed, the image forming apparatus cannot resume image printing. That is, the more the time it takes to curb the meandering speed of the intermediate transfer belt 10, the more the image forming apparatus has to wait to resume image printing thereby badly affecting the image printing efficiency of the image forming apparatus.
At the start of an image forming process, the attach-detach control unit 37 sends an abut signal to the first attach-detach device 13 and the second attach-detach device 14. The first attach-detach device 13 then lifts the primary transfer units 6a to 6c, while the second attach-detach device 14 lifts the primary transfer unit 6d so that the intermediate transfer belt 10 is abutted against the photosensitive drums 2a to 2d as shown in
The time required for the first attach-detach device 13 to start abutting the intermediate transfer belt 10 against one of the photosensitive drums 2a to 2c is considered to be T1ycm. To start the abutting process, the first attach-detach device 13 first has to lift the primary transfer units 6a to 6c and then abut them against the intermediate transfer belt 10. Thus, a small time lag occurs before the intermediate transfer belt 10 is actually abutted against one of the photosensitive drums 2a to 2c. That time lag can be used to set the time T1ycm by using information about the positional relation between the intermediate transfer belt 10 and the photosensitive drums 2a to 2c. Similar to the first attach-detach device 13, the time required for the second attach-detach device 14 to start abutting the intermediate transfer belt 10 against the photosensitive drum 2d is considered to be T1k, while the time required for the third attach-detach device 15 to start abutting the secondary transfer unit 9 against the intermediate transfer belt 10 is considered to be “T2”. For example, values for T, T1ycm, T1k, and T2 can be set as T=2395 milliseconds, T1ycm=T1k=380 milliseconds, and T2=275 milliseconds.
With respect to the time T at which the belt-rotating motor 19 attains the constant speed from the start of the image forming process, the attach-detach control unit 37 sends the abut signal to the first attach-detach device 13 at the time T-T1ycm. Similarly, the attach-detach control unit 37 sends the abut signal to the second attach-detach device 14 at the time T-T1k and to the third attach-detach device 15 at the time T-T2.
After completing the image forming process, the time required for the belt-rotating motor 19 to start decelerating from the constant speed is considered as T′. The time required for the first attach-detach device 13 to detach the intermediate transfer belt 10 from all the photosensitive drums 2a to 2c is considered to be T′1ycm. Similar to the first attach-detach device 13, the time required for the second attach-detach device 14 to detach the intermediate transfer belt 10 from the photosensitive drum 2d is considered to be T′1k, while the time required for the third attach-detach device 15 to detach the secondary transfer unit 9 from the intermediate transfer belt 10 is considered to be T′2.
With respect to the time T′ at which the belt-rotating motor 19 starts decelerating from the constant speed after completing the image forming process, the attach-detach control unit 37 sends the detach signal to the first attach-detach device 13 at the time T′-T′1ycm. Similarly, the attach-detach control unit 37 sends the detach signal to the second attach-detach device 14 at the time T′-T′1k and to the third attach-detach device 15 at the time T′-T′2.
Thus, in the sequence of operations shown in
As described above, the adverse effect of variation in tension in the direction along the width of the intermediate transfer belt 10 that is under rotation is reduced and the meandering speed of the intermediate transfer belt 10 can be curbed to maximum extent. As a result, it is possible to provide the image forming apparatus that performs quick and high quality image printing.
The attach-detach mechanism is configured to lift or lower the primary transfer units 6a to 6d so that the intermediate transfer belt 10 is abutted against or detached from the photosensitive drums 2a to 2d. However, same results can be achieved by configuring an attach-detach mechanism that lifts or lowers the photosensitive drums 2a to 2d so that they are abutted against or detached from the intermediate transfer belt 10. As described above, toner images on the photosensitive drums 2a to 2c are primary-transferred onto the intermediate transfer belt 10 by using the corresponding primary transfer units 6a to 6d (i.e., image forming apparatus with intermediate transfer mechanism). However, an image forming apparatus can also be used in which a toner image on a photosensitive drum is directly transferred onto a recording paper that is conveyed on a conveyer belt (i.e., image forming apparatus with direct transfer mechanism).
The intermediate transfer belt 10 is abutted against the photosensitive drums 2a to 2d and the secondary transfer unit 9 just when the intermediate transfer belt 10 attains a constant rotating speed. On the other hand, the intermediate transfer belt 10 is detached from the photosensitive drums 2a to 2d and the secondary transfer unit 9 just when the rotating speed of the intermediate transfer belt 10 starts declining from the constant rotating speed. Such mechanism is implemented to enhance the durability of the intermediate transfer belt 10. However, if the durability of the intermediate transfer belt 10 is not an issue, then an attach-detach mechanism can be configured such that the intermediate transfer belt 10 is abutted against the photosensitive drums 2a to 2d and the secondary transfer unit 9 before the intermediate transfer belt 10 attains a constant rotating speed. Such mechanism helps in curbing the meandering speed better. On the other hand, the attach-detach mechanism can be configured such that the intermediate transfer belt 10 is detached from the photosensitive drums 2a to 2d and the secondary transfer unit 9 after the rotating speed of the intermediate transfer belt 10 starts declining from the constant rotating speed.
According to an embodiment of the present invention, because the outer surface of a belt is abutted against an abutting member before the belt attains a constant rotating speed, the meandering speed of the belt can be curbed to maximum extent and the time required to curb the meandering speed can also be reduced. Moreover, when such a belt-rotating mechanism is implemented in an image forming apparatus, the meandering speed of the belt at the start of an image forming process can be curbed to maximum extent thereby achieving quick and high quality image printing.
Although the invention has been described with respect to specific embodiments for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art that fairly fall within the basic teaching herein set forth.
Number | Date | Country | Kind |
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2006-232899 | Aug 2006 | JP | national |