This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2018-178606 filed Sep. 25, 2018.
The present disclosure relates to an image forming apparatus and an image structure.
For example, an image forming method and image forming apparatuses described in Japanese Unexamined Patent Application Publication No. 2012-173520 (Description of Embodiments,
Japanese Unexamined Patent Application Publication No. 2012-173520 discloses an image forming method of providing a clear toner layer onto at least one of chromatic color toner layers formed on an image support.
Japanese Patent No. 4962196 discloses an image forming apparatus in which a base toner image is formed only in a region that corresponds to a monochromatic color toner image formed by a second image forming unit and in which the developing amount of the base toner image in a region corresponding to a central portion is smaller than the developing amount of the base toner image in a region corresponding to an end portion.
Japanese Unexamined Patent Application Publication No. 2010-224126 discloses an image forming apparatus in which, when a color toner image is formed onto a clear toner image formed on an intermediate transfer body, the color toner image is formed by using a threshold of a solid image density as an upper limit in accordance with the type of a recording medium.
Aspects of non-limiting embodiments of the present disclosure relate to suppressing occurrence of a transfer failure of an image that is formed on the basis of an instruction from a user regarding a recording medium that reduces the transferability of an image, whereas in the case where a monochromatic or polychromatic image including a base image is formed onto a surface of a recording medium by uniformly transferring the image onto the recording medium regardless of the type of the recording medium and without using a transparent image formation unit, occurrence of a transfer failure will not be suppressed.
Aspects of certain non-limiting embodiments of the present disclosure overcome the above disadvantages and/or other disadvantages not described above. However, aspects of the non-limiting embodiments are not required to overcome the disadvantages described above, and aspects of the non-limiting embodiments of the present disclosure may not overcome any of the disadvantages described above.
According to an aspect of the present disclosure, there is provided an image forming apparatus including an intermediate transfer unit that holds an image to be transferred onto a recording medium, a base image formation unit that forms a planar base image onto the intermediate transfer unit by using an opaque base image forming agent, the base image being brought into contact with and disposed onto an entire surface of the recording medium or a partial region of the surface of the recording medium, a transparent image formation unit that forms a transparent image onto the intermediate transfer unit by using a transparent image forming agent, a first control unit that performs control for transferring a monochromatic or polychromatic image including the base image formed on the intermediate transfer unit by the base image formation unit onto the recording medium, a second control unit that performs control for superposing a monochromatic or polychromatic image including the base image formed by the base image formation unit onto the transparent image formed on the intermediate transfer unit by the transparent image formation unit and for transferring a monochromatic or polychromatic image including the transparent image and the base image onto the recording medium, and a selection unit that selects the first control unit or the second control unit depending on a recording medium type.
Exemplary embodiments of the present disclosure will be described in detail based on the following figures, wherein:
In
Note that the term “image formation” used in the “base image formation unit 3” and the “transparent image formation unit 4” refers to forming an image, and the term “image formation” will hereinafter be used as a term having a similar definition to “forming an image”.
In such technical measure, the base image Ga may be any planar image as long as the image is formed by using an opaque base image forming agent and is brought into contact with and disposed onto the entire surface of the recording medium 1 or a partial region of the surface of the recording medium 1. Although the base image Ga may be a planar image, the area coverage thereof is not necessarily 100%.
In addition, the first control unit 6 may be any functional unit as long as the unit controls image formation processing that does not use the transparent image Gc, and the second control unit 7 may be any functional unit as long as the unit controls image formation processing that uses the transparent image Gc.
Furthermore, the wording “a monochromatic or polychromatic image including the base image Ga” implies that, in addition to a monochromatic image formed of only the base image Ga, a polychromatic image formed by superposing a color image Gb (see
The selection unit 8 may be any functional unit as long as the functional unit automatically or manually selects the first control unit 6 or the second control unit 7 depending on the type of the recording medium 1.
A representative example or an example of the image forming apparatus 20 according to the present exemplary embodiment will now be described.
In the present exemplary embodiment, as a representative example, the image forming apparatus 20 includes a color image formation unit 5 that forms the color image Gb onto the intermediate transfer unit 2 by using one or a plurality of color image forming agents excluding the transparent image forming agent as illustrated in
As an example, the base image Ga has a weight per unit area larger than that of a color image layer of at least one color component of the color image Gb. As the present exemplary embodiment, in the case where the base image Ga has a large weight per unit area, the surface of the recording medium 1 is completely covered with the base image Ga, and thus, there is no concern about exposure of the surface of the recording medium 1 at a portion of the base image Ga.
Here, as an example, the base image forming agent has an average particle diameter larger than that of the transparent image forming agent or that of the color image forming agent. The present exemplary embodiment focuses on the particle diameter of the base image forming agent in order to ensure the weight per unit area of the base image Ga.
As another example, the base image forming agent includes a spot color that is different from the color image forming agent. The present exemplary embodiment is intended to improve the image quality of the color image Gb with respect to a background portion of the base image Ga by using the base image forming agent that includes a spot color different from the color image forming agent.
In this case, as an example, the base image forming agent is white.
In addition, in the image forming apparatus 20 that includes a fixing unit (not illustrated in
As an example, the second control unit 7 weakens a transfer electric field more than the first control unit 6 does. As illustrated in
As an example, the first control unit 6 and the second control unit 7 are automatically selected by the selection unit 8. In the present exemplary embodiment, the first control unit 6 or the second control unit 7 is automatically selected depending on the type of the recording medium 1.
In addition, as a representative example, the selection unit 8 selects the second control unit 7 when the recording medium 1 has a high resistance value that is equal to or higher than a predetermined resistance value and includes a conductive agent contained in a medium base material thereof. In the present exemplary embodiment, when the recording medium 1 has a high resistance value and includes a conductive agent, the second control unit 7 is selected. In the present exemplary embodiment, although the “predetermined resistance value” may be suitably selected, when the surface resistance value of the recording medium 1 is higher than 10 log Ω, a transfer failure of a polychromatic image (a superposed image) is likely to occur, and thus, 11 log Ω may be selected as the predetermined resistance value (see Examples).
As another representative example, the selection unit 8 selects the second control unit 7 when the recording medium 1 has a high resistance that is equal to or higher than the predetermined resistance and has black color. In the present exemplary embodiment, when the recording medium 1 has a high resistance and is black, the second control unit 7 is selected.
As another representative example, the selection unit 8 selects the second control unit 7 when the recording medium 1 has a high resistance value that is equal to or higher than the predetermined resistance value and includes carbon black contained in the medium base material thereof. In the present exemplary embodiment, considering that carbon black that is internally added as a conductive agent to the recording medium 1 is the reason why the recording medium 1 is black in many cases, the second control unit 7 is selected when the recording medium 1 has a high resistance value and includes carbon black.
In the present exemplary embodiment, an image structure that is formed on the special recording medium 1 is also novel.
In other words, as illustrated in
Here, as an example, in the image structure, the base image Ga has a weight per unit area larger than that of a color image layer of at least one color component of the color image Gb.
The exemplary embodiment of the present disclosure will be described in further detail below with reference to the accompanying drawings.
Overall Configuration of Image Forming Apparatus
In
Image Forming Unit
In the present exemplary embodiment, each of the image forming units 22 (22a to 22f) includes a drum-shaped photoconductor 23, and the following devices are disposed around the photoconductor 23: a charging device 24, such as a corotron or a transfer roller, that charges the photoconductor 23, an exposure device 25, such as a laser-scanning device, that writes an electrostatic latent image onto the charged photoconductor 23, a developing device 26 that develops the electrostatic latent image written on the photoconductor 23 with a corresponding one of color component toners, a first transfer device 27, such as a transfer roller, that transfers the toner image formed on the photoconductor 23 onto the intermediate transfer body 30, and a photoconductor cleaning device 28 that removes residual toner on the photoconductor 23.
The intermediate transfer body 30 is stretched by a plurality of (three in the present exemplary embodiment) stretching rollers 31 to 33. For example, the stretching roller 31 is used as a driving roller that is driven by a drive motor (not illustrated), and the intermediate transfer body 30 is caused to move circularly by the driving roller. In addition, an intermediate-transfer-body cleaning device 35 that removes residual toner on the intermediate transfer body 30 after the second transfer process is disposed between the stretching rollers 31 and 33.
Second Transfer Device (Collective Transfer device)
As illustrated in
In addition, a transfer voltage VTR is applied to the counter roller 56 (also serving as the stretching roller 33 in the present exemplary embodiment) from a transfer power supply 60 via a power supplying roller 57, which has electrical conductivity, in such a manner that a predetermined transfer electric field is formed between the transfer roller 55 and the counter roller 56.
Note that, in the second transfer device 50 of the present exemplary embodiment, although the transfer roller 55 is disposed so as to be pressed into contact with the intermediate transfer body 30, the present disclosure is not limited to this configuration, and it is obvious that, for example, a belt transfer module in which the transfer roller 55 is used as one of stretching rollers and in which a transfer belt is stretched between the stretching rollers may be employed.
Fixing Device
As illustrated in
Sheet Transport System
As illustrated in
The sheet transport system 80 further includes a branched transport path 87 that branches off downward from a portion of the horizontal transport path 84, the portion being located further downstream than the fixing device 70 in a sheet-transport direction, and that enables the sheet S to be flipped over. The sheet S that has been flipped over at the branched transport path 87 returns to the vertical transport path 83 by being transported along a return transport path 88 and is transported along the vertical transport path 83 and the horizontal transport path 84 again. Then, an image is transferred onto the rear surface of the sheet S in the second transfer region TR, and the sheet S passes through the fixing device 70 and is ejected to the sheet ejection receiver 86.
The sheet transport system 80 further includes a position alignment roller 90 that aligns the position of the sheet S and that supplies the sheet S to the second transfer region TR, and each of the transport paths 83, 84, 87, and 88 is provided with a suitable number of transport rollers 91. A guide chute 93 that guides the sheet S that has passed through the position alignment roller 90 to the second transfer region TR is disposed at a position on the horizontal transport path 84 on the start side of the second transfer region TR. In the present exemplary embodiment, the single guide chute 93 is disposed between the position alignment roller 90 and the second transfer region TR, and metal chute members that are paired with each other are disposed so as to face each other, so that a guide path of the sheet S is controlled.
In addition, a manual sheet feeding unit 92 that enables manual feeding of sheets toward the horizontal transport path 84 is provided on the image forming apparatus housing 21 on the side opposite to the side on which the sheet ejection receiver 86 is provided.
Type of Sheet
Although examples of the sheet S that may be used in the present exemplary embodiment widely include a sheet having a low surface resistance value and a sheet having a high resistance value, in particular, the sheet S needs to be a sheet that may be used in an image forming apparatus that has an image formation mode (a base-image-included image formation mode) in which a base image (e.g., a white image) is formed onto a surface of a sheet and in which at least one of color images having several color components is formed onto the base image.
In the present exemplary embodiment, there is a technical problem in that a transfer failure occurs when a superposed image including a base image and a color image is transferred onto a sheet that reduces the transferability of an image (a sheet having a high resistance value and a low density), and it is found from an investigation that the cause of such a transfer failure is electric discharge that occurs during a transfer process.
In particular, a sheet that is used in the base-image-included image formation mode is, for example, a black sheet, and it is confirmed, by examining the characteristics of this type of black sheet, that a transfer failure is not observed when a black sheet having a low surface resistance value is used, whereas a transfer failure is observed when a black sheet having a high surface resistance value higher than 10 log Ω is used. Note that, although some white normal sheets and the like also have a high surface resistance value higher than 10 log Ω, since there is less need to form a base layer formed of a base image for this type of normal sheet, the above-mentioned technical problem of a transfer failure is less likely to be perceived as a problem, and a transfer failure is a new technical problem in the case of using a special sheet such as a black sheet having a high surface resistance value.
Accordingly, the present exemplary embodiment takes measures against a transfer failure that occurs when using a recording medium associated with low transferability such as, for example, a black sheet having a surface resistance value of 11 log Ω or higher, and in order to determine whether a sheet to be used is a sheet for which such measures against a transfer failure need to be taken, a sheet-type determination device 100 that determines the type of a sheet is provided as illustrated in
Sheet-Type Determination Device
In the present exemplary embodiment, as an example of the sheet-type determination device 100, an operation panel that serves as a user interface is provided with a sheet-type specification device 101 as illustrated in
In addition, as illustrated in
The determination device 110 includes a pair of determination rollers 111 and a pair of determination rollers 112 that are arranged side by side in the transport direction of the sheet S. One of the pair of determination rollers 111, which are located on an upstream side in the transport direction of the sheet S, is connected to a determination power supply 113, and the other of the pair of determination rollers 111 is grounded via a resistor 114. An ammeter 115 is disposed between one of the pair of determination rollers 112, which are located on a downstream side in the transport direction of the sheet S, and the ground. Note that the determination rollers 111 and 112 may also be used as transport members (such as the position alignment roller 90 and the transport rollers 91) for the sheet S or may be provided as different members from these transport members.
In the present exemplary embodiment, for example, assuming that a non-high resistance sheet having a surface resistance value of 10 log Ω/□ or lower is used as the sheet S, when the sheet S is disposed so as to extend across the pairs of determination rollers 111 and 112, a determination current from the determination power supply 113 flows in such a manner as to be divided into a component that flows across the pair of determination rollers 111 and a component that reaches the ammeter 115 located on the side of the pair of determination rollers 112 by flowing through the sheet S.
In contrast, assuming that a high-resistance sheet having a surface resistance value of 11 log Ω/□ or higher is used as the sheet S, since the surface resistance value of a high-resistance sheet is higher than that of a non-high resistance sheet, when the sheet S is disposed so as to extend across the pairs of determination rollers 111 and 112, the determination current from the determination power supply 113 is reduced by an amount equal to an impedance and flows across the pair of determination rollers 111, and only a small amount of the determination current reaches the ammeter 115 located on the side of the pair of determination rollers 112 by flowing through the sheet S. As a result, the surface resistance value of the sheet S is calculated by using a measured current that is measured by the ammeter 115 and an applied voltage of the determination power supply 113, so that the type of the sheet S is determined.
In addition, in the present exemplary embodiment, the determination device 110 is capable of determining whether the sheet S that is transported is black by using fluctuations in the output of an optical sensor 116 (e.g., a sensor that employs a method in which a light emitting element radiates light onto a surface of a sheet and in which a light receiving element receives the reflected light).
Driving Control System of Image Forming Apparatus
In the present exemplary embodiment, as illustrated in
Method of Determining Type of Sheet
In a method of determining the type of a sheet that is employed in the present exemplary embodiment, as illustrated in
Operation of Image Forming Apparatus
Next, assume the case where different types of sheets S are used in the image forming apparatus 20, which is illustrated in
In this case, one of the sheets S is supplied by one of the sheet-feeding containers 81 and 82 or the manual sheet feeding unit 92 and transported along a predetermined transport path toward the second transfer region TR. During the transportation, for example, the determination device 110 performs processing for determining the type of the sheet S before the sheet S reaches the second transfer region TR. Note that, in addition to the processing for determining the type of the sheet S performed by the determination device 110, the user may perform an operation of specifying the type of the sheet S by using the sheet-type specification device 101.
In the present exemplary embodiment, processing for determining the type of a sheet is performed before each of the image forming units 22 (22a to 22f) performs image formation.
In the present exemplary embodiment, it is determined whether the sheet S is one of the special high-resistance sheets Sb, which are sheets associated with low transferability, and when the sheet S is not any one of the special high-resistance sheets Sb, an operation in a first image formation mode of the base-image-included image formation mode is performed. When the sheet S is one of the special high-resistance sheets Sb, an operation in a second image formation mode of the base-image-included image formation mode is performed.
In the present exemplary embodiment, in the processing for determining the special high-resistance sheets Sb, as illustrated in
When it is assumed that the sheet S to be used is a black sheet, in the processing for determining the special high-resistance sheets Sb, as illustrated in
<First Image Formation Mode>
In the present exemplary embodiment, the first image formation mode is a base-image-included image formation mode that is selected when the sheet S is one of the non-special high-resistance sheets Sa. In the first image formation mode, for example, as illustrated in
<Second Image Formation Mode>
In the present exemplary embodiment, the second image formation mode is a base-image-included image formation mode that is selected when the sheet S is one of the special high-resistance sheets Sb. In the second image formation mode, for example, as illustrated in
In particular, in the present exemplary embodiment, the weight per unit area of the white image Gw is ensured to be larger than the weight per unit area of each of the color component images included in the color image GYMCK so as to maintain the quality of the base image favorable. In order to easily ensure the weight per unit area of the white image Gw, a white toner having an average particle diameter larger than that of each of the other color component toners is used. The white image Gw is set such that, when the white image Gw has an area coverage of 80% or more, the white image Gw becomes a solid image after being fixed in place by the fixing device 70.
Note that this setting is common to the first image formation mode.
As described above, the operation in the first image formation mode or the operation in the second image formation mode is performed on the sheet S, and then the sheet S undergoes the second transfer process in the second transfer region TR. Then, the sheet S that has undergone the second transfer process is subjected to a fixing treatment performed by the fixing device 70 and is ejected to the sheet ejection receiver 86. As a result, the above series of printing operations (image formation processing) are completed.
Image Formation Processing in Second Image Formation Mode
Here, a process of the image formation operation in the second image formation mode will be schematically described. As illustrated in
In this case, in the special high-resistance sheet Sb, gaps 131 are present between sheet fibers 130, which are sheet base materials of the special high-resistance sheet Sb, and for example, a conductive agent 132 formed of carbon black is internally added to the fibers 130. Thus, the intensity of the transfer electric field ETR that is required for the special high-resistance sheet Sb having a surface resistance value of 11 log Ω or higher is relatively high. In addition, in the situation in which the gaps 131 and the conductive agent 132 are scattered in the sheet base materials, it is inevitable that abnormal electrical discharge H is likely to occur during a transfer process.
In such a situation, when the abnormal electrical discharge H occurs in the second transfer region TR, the transferability of the toner that is located at the position where the abnormal electrical discharge H has occurred deteriorates, and a portion of the clear image GCL deposited on a surface of the intermediate transfer body 30 remains on the surface of the intermediate transfer body 30. In this case, since the color image GYMCK (blue image GMC) is formed on the intermediate transfer body 30 with the clear image GCL interposed therebetween, and the white image Gw is formed on the intermediate transfer body 30 with the color image GYMCK (blue image GMC) interposed therebetween, the adhesion strength between the color image GYMCK (blue image GMC) and the clear image GCL or the adhesion strength between the white image Gw and the color image GYMCK (blue image GMC) is smaller than the adhesion strength between the clear image GCL and the intermediate transfer body 30. Thus, there is only little concern that a portion of the color image GYMCK (blue image GMC) and a portion of the white image Gw will remain on the intermediate transfer body 30.
Consequently, in the present exemplary embodiment, although a portion of the clear image GCL is not transferred and remains on the intermediate transfer body 30 as illustrated in
Image Formation Processing in First Image Formation Mode for Special High-Resistance Sheet Sb
When it is assumed that the image formation processing in the first image formation mode is performed on one of the special high-resistance sheets Sb, as illustrated in
In this case, when the abnormal electrical discharge H occurs in the second transfer region TR, the transferability of the toner that is located at the position where the abnormal electrical discharge H has occurred deteriorates, and a portion (a magenta toner GM or a cyan toner GC) of the color image GYMCK (blue image GMC) directly deposited on the surface of the intermediate transfer body 30 is not transferred and remains on the surface of the intermediate transfer body 30. This results in occurrence of a missing portion of the color image GYMCK (blue image GMC) transferred to the special high-resistance sheet Sb, and the missing portion of the color image GYMCK (blue image GMC) is easily visually recognized in the transferred image G as illustrated in
Image Formation Processing in Second Image Formation Mode for White Image
When the white image Gw that is a base image on which the color image GYMCK is not formed is formed onto one of the special high-resistance sheets Sb, as illustrated in
In this case, when the abnormal electrical discharge H occurs in the second transfer region TR, a portion of the clear image GCL is not transferred and remains on the surface of the intermediate transfer body 30. However, the whole white image Gw is transferred onto the special high-resistance sheet Sb, and a missing portion of the clear image GCL does not affects the viewability. Therefore, as illustrated in
In contrast, when it is assumed that the image formation processing in the first image formation mode is performed on one of the special high-resistance sheets Sb, as illustrated in
In this case, when the abnormal electrical discharge H occurs in the second transfer region TR, the transferability of the toner that is located at the position where the abnormal electrical discharge H has occurred deteriorates, and a portion of the white image Gw directly deposited on the surface of the intermediate transfer body 30 is not transferred and remains on the surface of the intermediate transfer body 30. This results in occurrence of a missing portion of the white image Gw transferred to the special high-resistance sheet Sb, and the missing portions of the transferred white image Gw is easily visually recognized as illustrated in
Modification
In
This is because, in the second image formation mode, a monochromatic or polychromatic image including the white image Gw is formed onto the intermediate transfer body 30 with the clear image GCL interposed between the monochromatic or polychromatic image and the intermediate transfer body 30, and the images are transferred onto one of the special high-resistance sheets Sb by using the transfer electric field, and even if a portion of the clear image GCL, which is in contact with the intermediate transfer body 30, remains untransferred, this does not directly affect the quality of the transferred image, so that the transfer electric field may be set to be lower than that in the first image formation mode.
In Example 1, the image forming apparatus according to the above exemplary embodiment is embodied, and the property of an image being able to be transferred when the operation in the first image formation mode as the base-image-included image formation mode is performed on various sheets having different surface resistance values is evaluated.
The evaluation results are illustrated in
In this evaluation, in the case of a sheet having a surface resistance value of higher than 10 log Ω, a transfer failure is observed regardless of the density of the sheet.
Accordingly, the operation in the second image formation mode is performed on a special high-resistance sheet having a surface resistance value of 11 log Ω or higher, and it is confirmed that the likelihood of occurrence of a transfer failure is reduced.
In Example 2, the quality of a transferred image when the operation in the second image formation mode of the base-image-included image formation mode is performed onto one of the special high-resistance sheets Sb is evaluated.
In Example 2, as illustrated in
In Example 2, an image that has been transferred to the special high-resistance sheet Sb is examined, and it is confirmed that, although a portion of the clear image GCL remains on the intermediate transfer body 30, the quality of the transferred image is extremely favorable.
In contrast, in a comparative example, the quality of a transferred image when the operation in the first image formation mode of the base-image-included image formation mode is performed onto one of the special high-resistance sheets Sb is evaluated.
In the comparative example, as illustrated in
In the comparative example, an image that has been transferred to the special high-resistance sheet Sb is examined, and it is confirmed that a missing portion of the transferred blue image GMC as the color image GYMCK occurs as a result of a portion (the magenta toner GM or the cyan toner GC) of the blue image GMC remaining on the intermediate transfer body 30, so that a transfer failure becomes notable.
The foregoing description of the exemplary embodiments of the present disclosure has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in the art. The embodiments were chosen and described in order to best explain the principles of the disclosure and its practical applications, thereby enabling others skilled in the art to understand the disclosure for various embodiments and with the various modifications as are suited to the particular use contemplated. It is intended that the scope of the disclosure be defined by the following claims and their equivalents.
Number | Date | Country | Kind |
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2018-178606 | Sep 2018 | JP | national |
Number | Name | Date | Kind |
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7933528 | Yoshioka et al. | Apr 2011 | B2 |
20120219309 | Yoshioka | Aug 2012 | A1 |
20150029518 | Tashiro | Jan 2015 | A1 |
20160054669 | Hori | Feb 2016 | A1 |
20160154345 | Nagata | Jun 2016 | A1 |
Number | Date | Country |
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2010-224126 | Oct 2010 | JP |
4962196 | Jun 2012 | JP |
2012-173520 | Sep 2012 | JP |
Number | Date | Country | |
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20200096890 A1 | Mar 2020 | US |