Patent Application
20120288293
The present invention relates to a color image forming apparatus which uses a development process which uses a rotary for holding developing devices.
A full-color image forming apparatus equipped with a single image bearing member and a rotatable developing device supporting member (rotary) for supporting multiple developing devices, has long been known. This type of full-color image forming apparatus uses such a development process that sequentially forms multiple electrostatic latent images on the peripheral surface of the image bearing member, with a preset interval, and sequentially develops the electrostatic latent images with corresponding developing devices, one for one, which are sequentially changed in positioned with the preset interval.
An image forming apparatus, such as the above described one, that employs a rotatable developing device supporting member for holding multiple developing devices, different in the color of the toner they use, is referred to as an image forming apparatus of the rotary type. It sequentially forms multiple electrostatic latent images on its single image bearing member, with a preset chronological interval, and develops each of the multiple electrostatic latent images, with the use of the developing device dedicated thereto in terms of color, by switching the developing devices in position by rotating the rotary.
There have been proposed various methods for detecting the amount of developer in an image forming apparatus of the rotary type. One of them has been proposed in Japanese Laid-open Patent Application 2010-26497. According to the technology disclosed in this patent application, the rotary is positioned so that one of the developing devices in the rotary is held in such an attitude that the developer in the area above the nip between the developer bearing member and developer supplying member in this developing device is allowed to fall through the nip between the developer bearing member and developer supplying member, and the amount of developer in the developing device is computed by detecting the electrostatic capacity between the developer bearing member and developer supplying member. Also according to this patent application, in terms of the rotational direction of the rotary, the position in which the developer amount is to be detected is different from the position in which a developing device is used for developing an electrostatic latent image. Therefore, the amount of developer in a developing device in the position in which the developer amount is to be detected can be detected while a developing device (different in color of developer from developing device in detection position) is used for development.
As described above, a full-color image forming apparatus in which the position, in terms of the rotational direction of the rotary, in which a given developing device is used for development is different from the position in which the amount of developer in a developing device is detected, and the amount of developer in a given developing device is detected while another developing device which is different in the color of the developer therein from the given developing device is being used for development, suffers from the following problem.
That is, when the developing device which uses the first color is being used for development, the developer amount in this developing device (which is in development position), and the developer amount in the developing device which is on the upstream side of this developing device and on the downstream side of the developer amount detection position, in terms of the rotational direction of the rotary, are detected after the developing devices are used for the on-going image formation.
In the case of these developing devices, the developer in each developing device is not consumed after the developer amount in the developing device is detected. Therefore, the developer amount detected in the developer amount detection position accurately reflects the amount of the developer in the developing device immediately after the ending of the on-going image forming operation. Thus, there is no problem.
However, the developing device which is in the developer amount detection position when the developing device for the first color is in the development position, and the developing device which is on the upstream side of the developer amount detection position and on the downstream side of the development position in terms of the rotational direction of the rotary, are used for development after their developer amount is detected.
In the case of these developing devices, the developer in each of these developing devices is consumed after the developer amount in these developing devices are detected. Therefore, the developer amount in these developing device after the ending of the on-going image forming operation is different from the developer amount in these developing devices detected in the developer amount detection position, by the amount by which the developer in these developing devices were used for development after the detection of the developer amount in these developing devices.
That is, if the developer in these developing devices is used by a large amount after the detection of the developer amount therein, some of these developing devices may be out of developer at the end of the image forming operation, even if it was determined that there was a sufficient amount of developer in these developing devices when the developer amount in these developing devices was detected. In other words, in a case where a given developing device in a full-color image forming apparatus runs out of developer after the developer amount therein is detected, the technology disclosed in the aforementioned patent application cannot inform a user that the given developing device is out of developer.
Therefore, it is during the next printing operation that a user is informed for the first time that one of the developing devices is out of developer. In the worst case, a print which suffers from unwanted white spots is outputted, and then, the user is informed that one of the developing devices is out of developer.
One of the solutions to this problem is to detect the developer amount in all the developing devices after the ending of an on-going image forming operation. This method, however, requires some developing devices to be moved into the developer amount detection position to detect the developer amount therein at the end of the image forming operation. That is, it requires an additional time just for detecting the developer amount.
Another method for estimating the developer amount in a developing device is the so-called pixel counting method, which counts the number of pixels to which developer (toner) is to be adhered per image during development in order to estimate the amount by which developer is used during an on-going image forming operation. This method makes it possible to instantly estimate (determine) the developer amount in each developing device during development. Therefore, it does not require an additional time for developer amount detection; it does not waste time just for developer amount detection. However, the amount by which developer is consumed per pixel is not constant. This creates a problem. In a case where only several prints are made, this inconsistency with which developer is consumed per pixel amounts to little error in the estimation of the developer amount in each developing device. However, in a case where a large number of prints are made, the cumulation of the inconsistency amounts to a large error in the estimation of the developer amount.
Thus, the primary object of the present invention is to provide an image forming apparatus capable of accurately informing a user of the developer amount in each of the developing devices of the apparatus at the end of each image forming operation, without requiring additional time just for detecting the developer amount in each of the developing devices.
According to an aspect of the present invention, there is provided a color image forming apparatus comprising an image bearing member for carrying an electrostatic latent image; a plurality of developing devices for effecting a developing operation for developing the electrostatic latent image; a supporting member, supporting said developing devices, for moving said supporting member sequentially to a developing position opposing said image bearing member; a detecting device for effecting a detecting operation at a position different from the developing position for detecting information relating to a developer remainder in said developing device; deducing means for deducing a consumption amount of the developer from image information; and a determining portion for determining the developer remainder, wherein in color image formation, as to said developing device of said developing devices for which the detecting operation of said detecting device is effected after the developing operation therefor, said determining means determines the developer remainder from the information relating to the developer remainder detected by said detecting device, and as to said developing device of said developing devices for which the detecting operation of said detecting device is effected before the developing operation therefor, said determining means determines the developer remainder from the information relating to the developer remainder detected by said detecting device and the consumption amount deduced by said deducing means.
According to the present invention, even in a case where the developer amount in one of the developing devices of a full-color image forming apparatus is detected while another developing device of the apparatus is being used for development, a user can be accurately informed of the amount by which developer will be in each of developing devices at the end of the on-going image forming operation, without requiring an additional time just for detecting the developer amount in the developing device, the developer amount of which is detected while another developing device is used for development. These and other objects, features, and advantages of the present invention will become more apparent upon consideration of the following description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings.
Hereinafter, the image forming apparatuses in the preferred embodiments of the present invention are concretely described with reference to the appended drawings.
It forms an image on a sheet 11 of recording medium (as recording medium) based on the aforementioned electrical image formation signals inputted into the controller section 100 of the CPU of the apparatus, which functions as a controlling means. Not only does the controller section 100 exchange various electrical information with the host apparatus 200 and the control panel portion 300 of the image forming apparatus, but also, integrally controls the image forming operation of the apparatus following one of the preset control programs, and referential tables.
This image forming apparatus has a rotatable electrophotographic photosensitive member 1 (which hereafter will be referred to simply as “photosensitive drum 1”), which is an image bearing member which bears an electrostatic latent image on its peripheral surface. It has also a charge roller 2 and a laser scanner unit 3. The charge roller 2 is one of the means for processing the photosensitive drum 1, more specifically, the means for charging the photosensitive drum 1. The laser scanner unit 3 is the means for exposing the photosensitive drum 1.
The image forming apparatus has also: multiple (four in this embodiment) developing devices 5 as the means for developing an electrostatic latent image formed on the photosensitive drum 1, into a visible image formed of developer (toner); a transfer unit 6 as a transferring means; and a cleaning blade as the means for cleaning the photosensitive drum 1.
The photosensitive drum 1 is driven so that it rotates about its shaft in the direction indicated by an arrow mark a in
More specifically, the laser scanner unit 3 scans (exposes), at the exposure line A, the uniformly charged portion of the peripheral surface of the photosensitive drum 1, with a beam L of laser light it outputs while modulating the beam L in accordance with the information about each of the monochromatic images (obtained by separating image to be formed), which is inputted into the controller section 100 from the host apparatus 200. As a result, an electrostatic latent image is formed on the peripheral surface of the photosensitive drum 1. In this embodiment, an electrostatic latent image is formed by exposing the uniformly charged portion of the peripheral surface of the photosensitive drum 1 in accordance with the information of the image to be formed. The developing device 5 develops an electrostatic latent image on the peripheral surface of the photosensitive drum 1 into a visible image formed of developer (toner). The image forming apparatus in this embodiment has multiple (four) developing devices 5a -5d. The four developing devices 5a - 5d are supported by a rotary 50 as a developing device supporting member. The rotary 50 is rotatable about its central shaft while supporting the developing devices 5a -5d. The rotary 50 is structured so that it is rotatable about its shaft 51, while holding the multiple (four) developing devices 5a-5d, in order to sequentially place the developing devices 5a-5d in the development position H where each developing device contacts the photosensitive drum 1.
The rotary 50 is rotatable about its shaft 51 in order to place a specific developing device among the multiple (four) developing devices 5a-5d, in the development position H. The rotary 50 is provided with multiple (four) developing device slots dedicated to the developing devices 5a-5d, one for one. That is, in terms of the rotational direction of the rotary 50, each developing device slot occupies 90° in terms of the rotational direction of the rotary 50. The rotary 50 is rotatable by a multiple of 90° by an unshown driving means, such as a motor, which is under the control of the controller section 100 so that one of the developing devices 5a-5d is placed in the developing position H. Thus, the developing devices 5a-5d can be sequentially moved into the development position H where each developing device is made to oppose the photosensitive drum 1 to develop an electrostatic latent image on the peripheral surface of the photosensitive drum 1 into a visible image formed of toner (which hereafter may be referred to simply as toner image).
As the rotary 50 is rotated by 90°, the developing device 5 in the development position H is moved from the development position H (where it opposes photosensitive drum 1) to a position F. Then, as the rotary 50 is rotated for the second time by 90° (180° from development position H), the developing device in the position F is moved from the position F into a position E where the developer amount in the developer container 21 of the developing device is detected. As the rotary 50 is rotated for the third time by 90° (270° from development position H), the developing device in the position E is moved into a position G.
Each of the developing devices 5a-5d in this embodiment is such a developing apparatus that reversely develops an electrostatic latent image. It is of the contact type, and uses negatively chargeable nonmagnetic toner 12 as developer. Referring to
The transfer unit 6 is a transferring means for transferring a toner image on the peripheral surface of the photosensitive drum 1 onto a sheet 11 of recording medium. The transfer unit 6 in this embodiment has a primary transfer roller 62, a driver roller 63, a secondary transfer counter roller 64, and a tension roller 65. It has also an intermediary transfer belt 61 (as intermediary transferring member), which is flexible and is made of a dielectric substance. It is suspended and kept stretched by these rollers 62, 63, 64 and 64. The primary transfer roller 62 is kept pressed against the photosensitive drum 1 with the presence of the intermediary transfer belt 61 between itself and the photosensitive drum 1.
The area of contact between the photosensitive drum 1 and intermediary transfer belt 61 is the primary transfer nip J. There is a secondary transfer roller 66, which opposes the secondary transfer counter roller 64 with the presence of the intermediary transfer belt 61 between itself and the roller 64. The secondary transfer roller 66 is selectively switchable in position by an unshown mechanism, between a position in which it is kept pressed against the secondary transfer counter roller 64 with the presence of the intermediary transfer belt 61 between itself and the roller 64, and a position in which it is kept separated from the surface of the intermediary transfer belt 61.
Normally, the secondary transfer roller 66 is kept in the position in which it is kept separated from the intermediary transfer belt 61. It is moved, with a preset control timing, into the position in which it is used for the secondary transfer. The area of contact between the secondary transfer roller 66 and intermediary transfer belt 61 when the secondary transfer roller 66 is in the position in which it is used for the secondary transfer is the secondary transfer nip D. The image forming apparatus is provided with a belt cleaning device 67 for cleaning the surface of the intermediary transfer belt 61. The belt cleaning device 67 is positioned so that it opposes the tension roller 65 with the presence of the intermediary transfer belt 61 between itself and the tension roller 65.
The belt cleaning device 67 is switchable in position by an unshown mechanism, between a position (first position) in which its cleaning member is kept in contact with the image bearing surface of the intermediary transfer belt 61, and a position (second position) in which its cleaning member is kept separated from the image bearing surface of the intermediary transfer belt 61. Normally, the cleaning member of the cleaning device 67 is kept in the second position. It is moved into the first position with preset control timing. The cleaning blade 7 is a means for removing from the peripheral surface of the photosensitive drum 1, the toner remaining on the peripheral surface of the photosensitive drum 1 after the transfer (primary transfer) of a toner image from the peripheral surface of the photosensitive drum 1 onto the intermediary transfer belt 61. The toner removed by the cleaning blade 7 from the peripheral surface of the photosensitive drum 1 is stored in the cleaning means container 71.
As an image formation start signal is inputted into the image forming apparatus, the controller section 100 begins to drive an unshown main motor of the apparatus, whereby the photosensitive drum 1 begins to be rotated in the direction indicated by the arrow mark a in
The secondary transfer roller 66 and belt cleaning device 67 are kept in their second position where they are kept separated from the intermediary transfer belt 61. To the charge roller 2, a preset charge bias is applied, whereby the peripheral surface of the rotating photosensitive drum 1 is uniformly charged to a preset polarity (negative in this embodiment) and a preset potential level. Then, the uniformly charged portion of the peripheral surface of the photosensitive drum 1 is scanned by (exposed to) a beam L of laser light outputted from the laser scanner unit 3 while being modulated with the image formation signals which correspond to the yellow color component of the full-color image to be formed.
As a result, an electrostatic latent image, which reflects the image formation signals related to the yellow color component, is formed on the peripheral surface of the photosensitive drum 1. This electrostatic latent image is developed into a yellow (Y) toner image (developer image) by the developing device 5a in the development position H. In this embodiment, an electrostatic latent image is reversely developed with the use of negative toner, the intrinsic polarity of which is the same as the polarity (negative) to which the photosensitive drum 1 is charged. The yellow (Y) toner image is transferred (primary transfer) onto the surface of the intermediary transfer belt 61 in the primary transfer nip J. To the primary transfer roller 62, the primary transfer bias is applied with preset control timing. The primary transfer bias is preset in potential level, and is opposite (positive) in polarity to the toner. After the primary transfer, the peripheral surface of the photosensitive drum 1 is cleaned by the cleaning blade 7.
As the electrostatic latent image on the photosensitive drum 1 is developed into the yellow (Y) toner image, and transferred (primary transfer) onto the intermediary transfer belt 61, the rotary 50 is rotated by 90° in the direction indicated by an arrow mark b in
As the transfer (primary transfer) of the magenta (M) toner image onto the intermediary transfer belt 61 ends, the rotary 50 is rotated by 90° in the direction indicated by the arrow mark b in
As the transfer (primary transfer) of the cyan (C) toner image onto the intermediary transfer belt 61 ends, the rotary 50 is rotated by 90° in the direction indicated by the arrow mark b in
As a result, an unfixed full-color toner image is synthetically effected on the intermediary transfer belt 61 by the yellow (Y), magenta (M), cyan (C) and black (Bk) monochromatic toner images.
That is, one of the developing devices 5 is moved into the development position H (where it opposes photosensitive drum 1) by rotating the rotary 50 by the unshown driving means such as a motor. Then, an electrostatic latent image on the photosensitive drum 1 is developed into a toner image by the developing device 5 in the development position H. This operational sequence is sequentially carried out for the developing devices 5a, 5b, 5c and 5d to form an unfixed full-color toner image on the intermediary transfer belt 61.
Incidentally, the order in which the four monochromatic toner images, that is, yellow (Y), magenta (M), cyan (C) and black (Bk) toner images, are formed on the photosensitive drum 1 does not need to be limited to the order in which they are formed in this embodiment; it is optional.
Before the leading edge of the unfixed full-color toner image, made up of four monochromatic toner images and different in color, on the intermediary transfer belt 61 is made to reach the secondary transfer nip D (where secondary transfer roller 66 opposes secondary transfer counter roller 64) by the movement of the intermediary transfer belt 61, the secondary transfer roller 66 is moved into its first position (where it is kept in contact with intermediary transfer belt 61), and the belt cleaning device 67 also is moved into its first position (where it is kept in contact with intermediary transfer belt 61).
Meanwhile, the sheets 11 of recording medium in the unshown recording medium feeding section of the image forming apparatus are fed one by one into the main assembly of the apparatus from the recording medium feeding section while being separated from those in the feeding section, and are conveyed further into the main assembly. Then, each sheet 11 of recording medium is introduced by unshown registration roller unit, into the secondary transfer nip D, which is the area of contact between the secondary transfer roller 66 and intermediary transfer belt 61, with preset control timing. To the secondary transfer roller 66, secondary transfer bias is applied, which is opposite (positive) in polarity to the toner. With the application of the secondary transfer bias to the secondary transfer roller 66, the four monochromatic toner images (different in color and layered on the intermediary transfer belt 61), of which the full-color toner image is made on the intermediary transfer belt 61, are transferred together (secondary transfer) onto the sheet 11 of recording medium while the sheet 11 is conveyed through the secondary transfer nip D, remaining pinched between the intermediary transfer belt 61 and secondary transfer roller 66.
As the sheet 11 of recording medium is conveyed out of the secondary transfer nip D, it is separated from the surface of the intermediary transfer belt 61, and is introduced into a fixation unit 8, which is made up of a heat roller and a pressure roller. The heat roller and pressure roller are kept pressed against each other, forming the fixation nip between the two rollers; the area of contact between the two rollers is the fixation nip. The sheet 11 is conveyed through the fixation nip of the fixation unit 8. As the sheet 11 is conveyed through the fixation nip, the sheet 11 and the four monochromatic toner images, different in color, thereon are subjected to heat and pressure, whereby the four monochromatic toner images are fixed to the sheet 11 (while becoming mixed). After the sheet 11 is conveyed out of the fixation unit 8, it is discharged as a full-color print, into an unshown delivery section.
The secondary transfer residual toner, that is, the toner remaining on the image bearing surface of the intermediary transfer belt 61 after the separation of the sheet 11 of recording medium from the intermediary transfer belt 61, is removed by the belt cleaning device 67.
After the ending of an image forming operation in which only a single print is outputted, or an image forming operation in which multiple prints are outputted, the controller section 100 puts the image forming apparatus on standby, and waits for the inputting of the next image formation start signal. That is, the controller section 100 stops driving the photosensitive drum 1, laser scanner unit 3, intermediary transfer belt 61, etc. Further, it moves the secondary transfer roller 66 and belt cleaning device 67 into their second position (where they are kept separated from intermediary transfer belt 61).
In this embodiment, the four developing devices 5a-5d are the same in structure, although they are different in the color of the developer (toner) they store in their developer container 21.
The developer container 21 is a rectangular container, the lengthwise direction of which is parallel to the axial line of the photosensitive drum 1. Its bottom section has an opening 22, which extends in the lengthwise direction of the developer container 21. The opening 22 is positioned so that it faces the photosensitive drum 1 when the developing device 5 is in the development position H. The development roller 25 is positioned in parallel to the developer container 21 in such a manner that its peripheral surface faces the opening 22 of the developer container 21. It is rotatably supported by the developer container 21. More concretely, the lengthwise end walls of the developer container 21 are provided with an unshown pair of bearings, one for one, and the development roller 25 is supported by the unshown pair of bearings, by its lengthwise ends, one for one.
The developer application roller 24 is positioned in the developer container 21 in parallel to the development roller 25 in such a manner that when the developing device 5 is in the development position H, it is on the opposite side of the development roller 25 from the photosensitive drum 1. It also is rotatably supported by the developer container 21. More concretely, the lengthwise end walls of the developer container 21 are provided with an unshown pair of bearings, one for one, and the developer application roller 24 is supported by the unshown pair of bearings, by its lengthwise ends, one for one.
In this embodiment, the development roller 25 is 13 mm in external diameter. It is made up of a metallic core 28, a base layer 28a, and a surface layer 28b. The metallic core 28 is electrically conductive, and is 8 mm in external diameter. The base layer 28a is formed of silicone rubber, and covers the entirety of the peripheral surface of the metallic core 28. The surface layer 28b is formed of acrylic/urethane rubber, and is coated on the peripheral surface of the base layer 28a. The volume resistivity of the development roller 25 is in a range of 104 Ω.cm-1012 Ω.cm.
The developer application roller 24 is 15 mm in external diameter, and is made up of an electrically conductive metallic core 29, and a urethane sponge layer 29a. The metallic core 29 is 6 mm in external diameter. The urethane sponge layer 29a covers the entirety of the peripheral surface of the metallic core 29. Its pores are in connection with one another. The volume resistivity of the urethane sponge layer 29a is in a range of 104 Ω.cm-1012 Ω.cm.
The distance between the metallic core 28 of the development roller 25 and the metallic core 29 of the developer application roller 24 is 13 mm. The development roller 25 and developer application roller 24 are positioned so that the development roller 25 compresses the urethane sponge layer 29a of the developer application roller 24 by 1.0 mm.
The regulation blade 27 is a flexible member made of phosphor bronze, urethane rubber, etc. It is positioned so that its free edge rubs the peripheral surface of the development roller 25 to form the toner on the peripheral surface of the development roller 25 into a thin layer of toner after the coating of toner onto the peripheral surface of the development roller 25 by the developer application roller 24. The regulation blade 27 is attached to the top edge portion of the aforementioned opening 22 of the developer container 21, by its base portion.
The seal 26 is a flexible member. It is positioned so that its free edge contacts the development roller 25 to cover (seal) the gap between the bottom portion of the development roller 25 and the developer container 21 to prevent the toner in the developer container 21 from leaking.
Referring to
In this embodiment, the development roller 25 of the developing device 5a is in contact with the photosensitive drum 1. The development roller 25 develops an electrostatic latent image formed on the photosensitive drum 1, by being kept in contact with the photosensitive drum 1. That is, the developing device 5a uses the so-called contact developing method.
To the developing device 5 in the development position H, the force for driving the developing device 5, and the development bias, are inputted from unshown driving means and electric power source, respectively, of the main assembly of the image forming apparatus during image formation. The development roller 25 is driven so that it rotates in the direction indicated by an arrow mark e in
As the development roller 25 is rotated, the peripheral surface of the development roller 25 is coated with the toner 12 by the rotating developer application roller 24. Then, the toner 12 coated on the peripheral surface of the development roller 25 is formed into a thin layer of a preset thickness, and is conveyed by the subsequent rotation of the development roller 25 to the development position H where the development roller 25 opposes the photosensitive drum 1. To the development roller 25, a preset development bias (which in this embodiment is DC voltage) is applied from a development bias power source 13.
As the development bias is applied to the development roller 25, toner in the thin toner layer on the peripheral surface of the development roller 25 selectively transfer onto the pixels of the electrostatic latent image on the peripheral surface of the photosensitive drum 1, whereby the electrostatic latent image is developed into a toner image. The toner 12, which was not used for the development of the electrostatic latent image is returned into the developer container 21 by the subsequent rotation of the development roller 25, and is removed from the peripheral surface of the development roller 25 by the developer application roller 24, while the peripheral surface of the development roller 25 is coated again with the toner 12 by the developer application roller 24. This operational sequence is repeated to develop the electrostatic latent image on the peripheral surface of the photosensitive drum 1.
Next, the method, in this embodiment, for detecting the residual toner amount in the developing device 5 is described. In this embodiment, the toner amount detecting method based on pixel count, and the toner amount detecting method based on electrostatic capacity are used in combination.
First, the toner amount detecting method based on pixel count is described. The toner amount detection method based on pixel count uses a pixel counter 400, as a pixel counting means, which is capable of calculating the amount of light emitted by the laser scanner 3. More concretely, the number of pixels of the image to be formed, to which toner is to be adhered, is calculated by the pixel counter 400, based on the information of the image to be formed, and the amount by which the toner 12 (developer) will be used is estimated. The preset amount by which the toner 12 is to be used per pixel is stored in the main assembly memory, and the amount by which the toner 12 will be used is estimated based on the cumulative number of the pixels (to which the toner 12 is to be adhered) obtained by the pixel count 400 (That is, pixel counter 400, as estimating means, estimates amount of toner consumption, based on information of image to be formed).
Next, the residual toner amount detecting method of the electrostatic capacity measurement type is described. The surface layer of the developer application roller 24 in this embodiment is a porous layer. More concretely, the developer application roller 24 has a surface layer 29a made of urethane sponge, the pores of which are in connection with one another. The urethane sponge layer 29a, the pores of which are in connection with one another, has such a characteristic that the amount by which toner can be held in the urethane sponge layer 29a is affected by the “air-permeability” of the urethane sponge layer 29a, that is, one of the physical properties of a piece of sponge, the pores of which are in connection with one another.
This physical property called “air-permeability” indicates the amount by which air is allowed to pass through an object. That is, the smaller the opening of each of the surface pores of the urethane sponge layer 29a, the smaller in air-permeability the urethane sponge layer 29a. Further, the smaller and denser in the internal pore structure of the urethane sponge layer 29a, the smaller in air-permeability the urethane sponge layer 29a. On the contrary, the larger the urethane sponge layer 29a in the size of a surface pore, the greater it is in air-permeability. Further, the larger the urethane sponge layer 29a in the size of its internal cell, the greater it is in air-permeability.
In other words, the amount by which toner can be held in the urethane sponge layer 29a is affected by the change in the air-permeability of the urethane sponge layer 29a. At this time, the aforementioned method for measuring the amount of air-permeability of the urethane sponge layer 29a is described. Referring to
Then, a hose 302, which is larger in internal diameter than the hole 301a is attached to the acrylic plate 301 in such a manner that the hole 301a becomes continuous with the hole of the hose 302. Then, the amount of air-permeability of the urethane sponge layer 29a is measured with an air-permeability measurement device 303 (for example, KZ type air-permeability tester: product of Daiei Kagaku Seiki MFG Co., Ltd.) while suctioning air by a pump 304, which is 10.8 [liter/min] in capacity, without the presence of the developer application roller 24. According to the experiments carried out by the inventors of the present invention, the urethane sponge layer 29a was desired to be no less than 2 [liter/min] in air-permeability. Shown in
Shown in
That is, there is a correlation between the amount by which toner is held in the urethane sponge layer 29a of the developer application roller 24 and the electrostatic capacity between the developer application roller 24 and development roller 25. In other words, the amount of the toner in the urethane sponge layer 29a of the developer application roller 24 can be obtained (estimated) by measuring the electrostatic capacity between the developer application roller 24 and development roller 25, and the residual amount of toner (developer) in the developer container 21 can be estimated based on the amount of toner in the urethane sponge layer 29a of the developer application roller 24.
In this embodiment, a residual toner amount detecting device 100a, which is the means for detecting the developer amount in the developer container 21, is in a detection position E, which is different from the development position H where the development roller 25 opposes the photosensitive drum 1 as shown in
In order to detect the residual toner amount in the developer container 21, the residual toner amount detecting device 100a applies a residual toner amount detection bias to the metallic core 29 of the developer application roller 24 from a bias application power source 31. The residual toner amount detecting device 100a in this embodiment is 5 kHz in frequency and 200 V in Vpp. The alternating voltage induced in the electrically conductive metallic core 28 of the development roller 25 is rectified by a detection circuit 9. Then, the voltage itself of the DC voltage obtained by the rectification, or the electrical signals obtained by digitizing the DC voltage, is outputted as the information about the electrostatic capacity. It is from this output that the residual toner amount in the developer container 21 is determined by the controller section 100.
Next, the method for measuring (determining) the toner amount in the developer container 21 with use of the combination of the aforementioned pixel counter 400 and the residual toner amount detecting device 100a (which detects electrostatic capacity between metallic cores 29 and 28) while an image is formed is described.
Referring to
In other words, the residual toner amount detecting device 100a detects the residual toner amount in the developing device 5c while the developing device 5a is used for development. It detects the residual toner amount in the developing device 5d while the developing device 5b is used for development. It detects the residual toner amount in the developing device 5a while the developing device 5c is used for development. Further, it detects the residual toner amount in the developing device 5b while the developing device 5d is used for development is detected.
Referring to
The amount by which the cyan (C) toner is used for developer by the developing device 5c is detected by the pixel counter 400 while the developing device 5a is used for development. The value obtained by subtracting the residual toner amount in the developer container 21 of the developing device 5c detected by the residual toner amount detecting device 100a before the developing device 5c is used for development, from the amount of the cyan (C) toner consumption computed by the pixel counter 400 is the residual toner amount in the developer container 21 of the developing device 5c after the development (ending of the on-going image forming operation). An operation similar to that carried out for the developing device 5c is carried out for the developing device 5d.
That is, the residual toner amount in the developing device 5a and that in the developing device 5b at the end of the on-going image forming operation are those detected by the residual toner amount detecting device 100a, whereas the residual toner amount in the developing device 5c and that in the developing device 5d at the end of the on-going image forming operation are the values obtained by subtracting the amounts of toner consumption estimated by the pixel counter 400 from the values obtained by the residual toner amount detecting device 100a. That is, for the developing devices, the residual developer amount of which is detected by the residual toner amount detecting device 100a after they are used for development in a color image forming operation, the controller section 100 determines the residual developer amount therein based on the information regarding the residual toner amount detected by the residual toner amount detecting device 100a. For the developing devices, the residual developer amount of which is detected by the residual toner amount detecting device 100a, the controller 100 determines the residual developer amount therein based on a combination of the information regarding the residual developer amount detected by the residual toner amount detecting device 100a, and the information regarding the developer consumption amount estimated with the use of the pixel counter 400.
The residual toner amounts obtained through the above described processes are compared with a preset threshold value for predicting the remaining length of the service life of the developing device 5. If the residual toner amount in any of the developing devices 5 is no more than the threshold value (no more than preset amount), the control section 100 displays, on the display 300a of the control panel 300, a message for warning a user that the developing device 5 is close to the end of its service life.
Referring to
Next, in Step S4, the developing device 5b for magenta (M) color is moved into the development position H. Then, the residual toner amount RBk in the developer container 21d of the developing device 5d (for black (Bk) color) in the developer amount detection position E is detected by the residual toner amount detecting device 100a while the electrostatic latent image on the photosensitive drum 1 is developed into a magenta (M) toner image by the developing device 5b (Step S5).
Next, in Step S6, the developing device 5c for cyan (C) color is moved into the development position H. Then, in Step S7, the amount PixC by which cyan (C) toner will be consumed by the on-going image forming operation is calculated by the pixel counter 400 while the electrostatic latent image on the photosensitive drum 1 is developed into a cyan (C) toner image by the developing device 5c. Further, the residual toner amount RY in the developer container 21a of the developing device 5a (for yellow (Y)) in the detection position E is detected by the residual toner amount detecting device 100a.
Next, in Step S8, the developing device 5d (for black (Bk) color) is moved into the development position H. Then, in Step S9, the amount PixBk by which black (Bk) toner will be consumed by the on-going image forming operation is calculated by the pixel counter 400 while the electrostatic latent image on the photosensitive drum 1 is developed into a black (Bk) toner image by the developing device 5d. Further, the residual toner amount RM in the developer container 21b of the developing device 5b (for magenta (M)) in the detection position E is detected by the residual toner amount detecting device 100a.
Next, in Step S10, it is determined whether or not the residual toner amount RY in the developer container 21a of developing device 5a (for yellow (Y) color) detected in Step S7 is no more than the preset threshold value. If it is no more than the threshold value, the control section 100 advances to Step S11 in which it displays a warning about the service life of the developing device 5a (for yellow (Y) color), on the display 300a of the control panel 300. If the residual toner amount RY in the developer container 21a of the developing device 5a (for yellow (Y) color) detected in Step S7 is no less than the preset threshold value, the control section 100 advances to Step S12.
Next, in Step S12, it is determined whether or not the residual toner amount RM in the developer container 21b of the developing device 5b (for magenta (M) color) detected in Step S9 is no more than the preset threshold value. If it is no more than the threshold value, the control section 100 advances to Step S13, in which it displays a warning about the service life of the developing device 5b (for yellow (Y) color), on the display 300a of the control panel 300. If the residual toner amount RM in the developer container 21b of the developing device 5b (for yellow (Y) color) detected in Step S12 is no less than the preset threshold value, the control section 100 advances to Step S14.
Next, in Step S14, the controller section 100 subtracts the amount PixC by which the cyan (C) toner in the developing device 5c would have been consumed by development, and which was obtained in Step S7 by the pixel counter 400 while the developing device 5c is used for development, from the residual toner amount RC in the developer container 21c in the developing device 5c (for cyan (C) color) detected in Step S3. If the difference is no more than the preset threshold value, the controller section 100 advances to Step S15, in which it displays a warning about the service life of the developing device 5c (for cyan (C) color), on the display 300a of the control panel 300.
Further, if the difference is no less than the preset threshold value, the controller section 100 advances to Step S16.
Next, in Step S16, the controller section 100 subtracts the amount PixBk by which the black (Bk) toner in the developing device 5d would have been consumed by development, and which was obtained in Step S9 by the pixel counter 400 while the developing device 5d is used for development, from the residual toner amount RBk in the developer container 21d in the developing device 5d (for black (Bk) color) detected in Step S5. If the difference is no more than the preset threshold value, the controller section 100 advances to Step S17, in which it displays a warning about the service life of the developing device 5d (for black (Bk) color), on the display 300a of the control panel 300.
Also, in Step S16, if the difference is no less than the preset threshold value, the controller section 100 advances to Step S18, in which it ends the on-going image forming operation.
That is, in the case of the developing device 5a, which is for developing an electrostatic latent image on the photosensitive drum 1 into a visible image of yellow (Y) color (first color), the residual toner amount (information about residual developer amount) in its developer container 21a detected in the developer amount detection position E by the residual toner amount detecting device 100a after the developing device 5a is used for the on-going image forming operation is used as the residual toner amount RY. Also in the case of the developing device 5b, which is for developing an electrostatic latent image on the photosensitive drum 1 into a visible image of magenta (M) color (second color), and which is on the upstream side of the development position H and on the downstream side of the developer amount detection position E in terms of the rotational direction of the rotary 50, when the developing device 5a is in the development position H, as shown in
On the other hand, in the case of the developing device 5c, which is in the developer amount detection position E when the developing device 5a is in the development position H, and also, in the case of the developing device 5d, which is on the upstream side of the developer amount detection position E and on the downstream side of the development position 11 (where developing device 5 opposes photosensitive drum 1), in terms of the rotational direction of the rotary 50, when the developing device 5a is in the development position H, the controller section 100 subtracts the value (as amount Pix by which toner in developing device 5c will be consumed during on-going image forming operation) estimated by the pixel counter 400, from the value obtained (as residual developer amount R in developing device) by the residual toner amount detecting device 100a in the developer amount detection point E. Then, it uses the differences (RC−PixC) and (Rbk−PixBk) as the residual developer amount in the developing device 5c and the residual developer amount in the developing device 5d, respectively.
In this embodiment, the length of time for the residual toner amount detecting device 100a to detect the residual amount of toner (developer) in the developer container 21 of the developing device 5 is set to be shorter than the length of time for the developing device 5 to use for development. Therefore, the controller section 100 detects the residual toner (developer) amount in the developer container 21 of the developing device 5 with the use of the residual toner amount detecting device 100a each time an image is formed.
However, there are sometimes occasions in which the length of time necessary for the residual toner amount detecting device 100a to detect the residual toner (developer) amount in the developer container 21 of the developing device 5 is longer than the length of time necessary for the developing device 5 to use for development. All that is necessary in such a case is that the controller section 100 detects the residual toner (developer) amount in the developer container 21 of the developing device 5 with the use of the residual toner amount detecting device 100a only with a preset timing, and reduces the image forming apparatus in image formation speed only during the detection of the residual toner (developer) amount.
With the use of the above described operational sequence for detecting the residual toner amount in the developer container 21 of the developing device 5, it is possible to inform a user of the precise amount of residual toner amount of the developer container 21 of the developing device 5, without requiring a specific length of time just for detecting the residual toner amount. As long as a user replaces the developing device 5 based on this information about the residual amount of toner in the developing device 5, it is possible to obtain images which do not suffer from unwanted white spots.
As described above, in this embodiment, the image forming apparatus employs the residual toner amount detecting device 100a, which measures the electrostatic capacity between the developer application roller 24 and development roller 25 to determine the amount of toner (developer) in the urethane sponge layer 29a of the developer application roller 24, and then, determines the residual amount of toner (developer) in the developer container 21 based on the amount of toner in the urethane sponge layer 29a. However, the present invention is also compatible with a residual toner amount detecting method other than the one used in this embodiment. While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth, and this application is intended to cover such modifications or changes as may come within the purposes of the improvements or the scope of the following claims.
This application claims priority from Japanese Patent Application No. 106016/2011 filed May 11, 2011 which is hereby incorporated by reference.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2011-106016 | May 2011 | JP | national |
