Patent Grant
9977399
Field of the Invention
The present invention relates to an image forming apparatus which performs a transfer output control at the time of forming an image.
Description of the Related Art
In recent years, in an image forming apparatus, for example, a copying machine or a laser beam printer, in order to obtain a high quality image even in a case where the environment of the installation site thereof is changed, various controls have been performed in the image forming process. For example, in a case where a high voltage is applied to an image forming component, abnormal discharge may occur according to the environment (temperature and humidity). Since the occurrence of the abnormal discharge greatly influences good or bad image quality, the occurrence of the abnormal discharge is prevented by changing the image forming condition according to the above-described factors.
As the control performed in the related art, there is ATVC (Active Transfer Voltage Control) of applying a constant current to a transfer roller which is to be applied with a high voltage before image formation and performing application of a constant voltage at the time of image formation by using a voltage value applied to the constant current circuit. This control copes with a change in resistance of the transfer roller according to a change of the environment.
However, this control method does not cope with a change in atmospheric pressure. Therefore, for example, when the apparatus is used at a high-altitude area where the atmospheric pressure is low, the image may be abnormal. When high voltages are applied to a transfer unit and a separation charge removal unit having different application polarity at a high altitude based on only the environment condition of temperature and humidity, leakage as abnormal discharge occurs between the two components (in a gap). Accordingly, deterioration in image quality occurs due to a shortage of a transfer current or the like, or damage to an electric element on a board occurs due to a flow of an excessive current according to the leakage.
The relationship between a leakage occurrence voltage and atmospheric pressure is known as the Paschen's law. In a case where the gap is maintained constant, a discharge starting voltage is decreased as the atmospheric pressure becomes low, and the abnormal discharge such as leakage easily occurs as the altitude become high.
With respect to the abnormal discharge, for example, Japanese Patent Laid-Open No. 5-88434 discloses an apparatus where an atmospheric pressure detection sensor is provided to an image forming apparatus and a control device changes an image forming condition according to an output of the sensor.
In addition, Japanese Patent Laid-Open No. 2010-48960 discloses an apparatus where, without providing an atmospheric pressure detection sensor, a dedicated leakage detection circuit which detects a leakage current occurring at the time of applying a high voltage is provided to a high-voltage applying unit which applies a high voltage to a transfer unit to detect the leakage current occurring in the state where the atmospheric pressure is low and to change an image forming condition.
However, in the image forming apparatus disclosed in Japanese Patent Laid-Open No. 5-88434, an atmospheric pressure sensor needs to be newly installed. In addition, even in the atmospheric pressure condition that the leakage easily occurs due to a low atmospheric pressure, under a high-temperature high-humidity environment condition where a resistance value of an object which a high voltage is to be applied is decreased, the voltage may not reach the leakage occurrence voltage. Even in a case where there is no need to decrease the applied voltage, the control of decreasing the applied voltage is performed based on only the atmospheric pressure condition, so that deterioration in image quality may occur due to a shortage of the transfer current.
In addition, in the image forming apparatus disclosed in Japanese Patent Laid-Open No. 2010-48960, since the leakage detection circuit is configured by arranging dedicated patterns for leakage detection with slight narrow spacing in high-voltage output lines in a high-voltage power supply board, it is not possible to accurately detect whether or not the leakage occurs between image forming components where the leakage actually occurs.
The invention is to provide an image forming apparatus capable of determining occurrence of abnormal discharge occurring in a transfer unit in view of above-described problem.
According to an aspect of the invention, there is provided an image forming apparatus which forms an image on a recording material, including a transfer unit which transfers a toner image formed on an image bearing member to a recording medium, an applying unit which applies a predetermined current or voltage to the transfer unit, a detection unit which detects a voltage value with respect to the predetermined current applied by the applying unit or a current value with respect to the predetermined voltage applied by the applying unit, an environment detection sensor which detects an environment, and a determination unit which compares a detection result of the detection unit with a predetermined value according to a detection result of the environment detection sensor to determine whether or not predetermined discharge occurs in the transfer unit.
According to the invention, it is possible to accurately determine whether or not the abnormal discharge occurs in a transfer portion. In addition, by determining an applied voltage or current at the time of image formation according to the above determination, it is possible to avoid an abnormal image or damage to an electric element.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
(Configuration of Image Forming Apparatus)
A sheet cassette 17 contains a sheet 16 which is a recording medium. The sheet 16 is conveyed to a pair of conveying rollers 8 by rotation of a feed roller 15. The sheet 16 passing between the pair of conveying rollers 8 is further conveyed to a pair of registration rollers 10. The pair of registration rollers 10 conveys the sheet 16 to a nip between a transfer roller 5 which is a transfer unit and a photosensitive drum 1. The nip is a portion which transfers a toner image formed on the photosensitive drum 1 which is an image bearing member having a photoconductive layer such as an OPC or an a-Si to the sheet 16 and is called a transfer nip.
In the formation of the toner image on the photosensitive drum 1, after the surface of the photosensitive drum 1 is uniformly charged by a charging device 2, a latent image is formed on the surface of the photosensitive drum 1 through exposing according to image information by an exposing device 3. The formed latent image is attached to a developer (toner) to be developed by a developing device 4.
A toner image formed on the photosensitive drum 1 is applied with electric charges (transfer bias) having a polarity opposite to that of the toner from the rear side of the sheet 16 by the transfer roller 5 so as for the toner image on the photosensitive drum 1 to be adsorbed to the sheet 16, so that the toner image is transferred to the sheet 16. On the other hand, the residual toner which is not transferred to the sheet 16 and remains on the photosensitive drum 1 is removed from the surface of the photoconductor drum by a cleaner 7.
The sheet 16 to which the toner image is transferred is neutralized by a separation charge removal needle 6 in order to allow the sheet to be easily separated from the photosensitive drum 1, so that the sheet is separated from the photosensitive drum 1. In the state where a non-fixed toner image is borne on the surface of the sheet, the sheet 16 separated from the photosensitive drum 1 is conveyed to a fixing nip between a pressure roller 11 and a fixing film 12 constituting a fixing device 14. In the fixing device 14, the toner image is fixed on the sheet 16. After that, the sheet 16 is discharged outside from the image forming apparatus S by a discharge roller 13.
Next, transferring of the toner to the sheet 16 will be described in detail.
The toner image developed on the photosensitive drum 1 is moved to the transfer nip where the photosensitive drum 1 and the transfer roller 5 face each other by the rotation of the photosensitive drum 1. At the timing when the sheet 16 is conveyed to the transfer nip by the pair of registration rollers 10, a DC voltage having a polarity opposite to that of the developer is applied from a transfer high-voltage circuit 21, which is an applying unit, of the high-voltage power supply unit to the transfer roller 5. In addition, the transfer high-voltage circuit 21 includes a constant current circuit and a constant voltage circuit to apply a plus DC voltage having a polarity opposite to that of the toner according to the embodiment to the transfer roller 5 during the image formation. As a result, the toner image attached on the photosensitive drum 1 is sequentially electrostatically transferred to the sheet 16.
As illustrated in
In addition, in the embodiment, a contact transfer roller method where the transfer roller is in contact with the photosensitive drum 1 is used. Besides, an intermediate transfer belt method where the toner image is transferred to a transfer belt and, after that, the toner image is further transferred to the sheet 16 may be used.
In addition, in the embodiment, an abnormal discharge (predetermined discharge) phenomenon where air insulation between two members which are in contact with each other or separated by a predetermined distance from each other is destructed so as to allow a leakage current to be flowed is simply called “leakage”.
(Transfer Roller)
Next, the transfer roller 5 as a transfer member which is a transfer unit according to the embodiment will be described.
In the embodiment, the contact transfer roller method where the transfer roller is in contact with the photosensitive drum 1 is used. However, a transfer roller having a single-layer structure is used as the transfer roller 5. The transfer roller 5 is an ion conductive rubber roller configured with mainly a metal shaft body and a conductive foamed body layer made of a sponge rubber obtained by foaming a mixed rubber of an acrylonitrile butadiene rubber (NBR) and a hydrin rubber in an outer circumference thereof.
The metal shaft body constituting the transfer roller 5 is not particularly limited, but a core made of a solid body made of a metal, a cylindrical body made of a metal of which interior is dug out to be hollow, or the like may be used. As a metal material, there are iron, aluminum, and the like, and it is not particularly limited.
The conductive foamed body layer is preferably set to have a hardness in a range of 20 to 35°/500 gf in Asker C (sponge hardness meter). In addition, the resistance value is preferably in a range of 1.0×106 to 1.0×108Ω, more preferably in a range of 1.0×107 to 1.0×108Ω. As a matrix component, there are ethylene propylene diene rubber (EPDM), acrylonitrile butadiene rubber (NBR), and the like. The matrix component is mixed with a hydrin rubber which is added with an ion conductive agent.
The product is formed with the formed material obtained by compounding an electronic conductive agent as a resistance adjusting agent, a foaming agent, a foaming assistant, a softener, a plasticizer, a filler, a vulcanizing agent, and a vulcanizing accelerator thereto.
As the electronic conductive agent, there are carbon black, graphite, a metal oxide such as a solid solution of a zinc oxide and an aluminum oxide, a solid solution of a tin oxide and an antimony oxide, and a solid solution of an indium oxide and a tin oxide. These materials are used alone or in a combination of two or more thereof.
In addition, as the foaming agent, there are dinitrosopentamethylenetetramine (DPT), azodicarbonamide (ADCA), 4,4-oxybisbenzenesulfonyl hydrazide (OBSH), and the like, and these materials are used alone or in a combination of two or more thereof.
(Control of Transfer-Roller Applied Current and Leakage Threshold Voltage)
Herein, “before image formation” denotes “before the toner image formed on the photosensitive drum 1 which is an image bearing member is transferred to the sheet 16 which is a recording medium conveyed to the transfer nip”. More specifically, the “before image formation” denotes “during a preparation operation of the image formation”.
The voltage-current characteristic of the transfer roller 5 is changed according to a change of temperature and humidity of the environment. A curve a plotted with circles in
If the CPU 20 determines that the abnormal discharge occurs, the CPU decreases the current value and compares the detection result (D of
If the CPU 20 determines that the abnormal discharge occurs, the CPU decreases the current value and compares the detection result (E of
The abnormal discharge occurring in the transfer roller 5 is caused as follows. Since the separation charge removal needle 6 is arranged near the transfer roller 5, the abnormal discharge such as a leakage current flowing in a gap between the transfer roller and the separation charge removal needle occurs according to the situation of the atmospheric pressure or the temperature and humidity. Therefore, whether or not the abnormal discharge occurs is different among apparatuses because even the same units have a difference in surface shape or position thereof.
In addition, the abnormal discharge between the transfer roller 5 and the separation charge removal needle 6 more easily occurs in the low temperature environment than the high temperature environment. This is because the resistance value of the transfer roller 5 in the low temperature environment is higher than that of the high temperature environment and thus, in order to satisfy the transfer function, a higher voltage needs to be applied, so that the abnormal discharge easily occurs. In addition, similarly, with respect to the humidity, since the resistance value of the transfer roller 5 in the low humidity environment is higher than that of the high humidity environment, in order to satisfy the transfer function, a higher voltage needs to be applied, so that the abnormal discharge easily occurs.
In addition, a curve b plotted with squares in
Herein, similarly to the above-described high-temperature high-humidity environment, the current values and the leakage threshold voltage values of the transfer roller 5 in the low-temperature low-humidity environment (L/L) and the normal-temperature normal-humidity environment (N/N) (in the embodiment, 25° C./50%) are obtained through an experiment, and the current values and the threshold voltage values are stored in the memory 19 of the controller in advance (refer to
(Control Flow)
First, if an operator pushes a copy start button, the signal is received, a pre-rotation as an image forming preparation operation is started. The pre-rotation denotes a rotation before the image forming process of the photosensitive drum 1 accompanying various initialization operations. For example, a cleaning operation for the photosensitive drum 1, a cleaning operation for the transfer roller 5, and other various initialization operations such as supplying power to a heater in the fixing device 14 to heat the pressure roller 11 are included. In the embodiment, the environment is determined by a detection value of the environment detection sensor 18 (S1). Hereinafter, in the flowchart, it is assumed that the low-temperature low-humidity environment is detected.
In addition, as described above, under the respective environments (low-temperature low-humidity environment, normal-temperature normal-humidity environment, and high-temperature high-humidity environment), voltage values (threshold voltage values) detected when the abnormal discharge (predetermined discharge) does not occur at the time of changing the value of the constant current applied as a transfer bias are stored in the memory 19 of the controller (refer to
The CPU 20 flows the constant current of 5 μA (first current value) as a bias current from a constant current circuit of the transfer high-voltage circuit 21 to the transfer roller 5 and detects the voltage at the time by using the transfer high-voltage detection circuit 22 (S2). Next, the CPU 20 compares the detected voltage with the threshold voltage value (+3300 V in the low-temperature low-humidity environment) at the time of the constant current of 5 μA stored in the memory 19 and determines whether or not the detected voltage detected in S2 exceeds +3300 V (S3).
If the detected voltage exceeds the threshold voltage value of +3300 V, it is determined that the abnormal discharge (predetermined discharge) does not occur (S4). Next, the value obtained by multiplying the environment coefficient and the value detected in S2 is determined as the transfer voltage value for the time of the image formation (S5).
In a case where the detected voltage detected in S2 is equal to or lower than the threshold voltage value of +3300 V in S3, the CPU 20 determines that the abnormal discharge (predetermined discharge) occurs due to the influence of the atmospheric pressure, and the CPU flows 4 μA (second current value) by decreasing the constant current value flowed to the transfer roller 5 by 1 μA and detects the voltage value at this time by using the transfer high-voltage detection circuit 22 (S6). The CPU 20 determines whether or not the detected voltage detected in S6 exceeds the threshold voltage value (+2700 V in the low-temperature low-humidity environment) at the time of the constant current of 4 μA stored in the memory 19 (S7).
If the detected voltage exceeds the threshold voltage value of +2700 V, the CPU 20 determines that the abnormal discharge (predetermined discharge) does not occur (S8). Next, the value obtained by multiplying the environment coefficient and the value detected in S6 is determined as the transfer voltage value for the time of the image formation (S9).
In a case where the voltage detected in S6 is equal to or lower than +2700 V, the CPU 20 determines that the abnormal discharge (predetermined discharge) occurs, and the CPU flows the constant current of 3 μA (third current value) by further decreasing the constant current value by 1 μA and detects the voltage value at this time by using the transfer high-voltage detection circuit 22 (S10). The CPU determines whether or not the detected voltage detected in S10 exceeds the threshold voltage value (+2200 V in the low-temperature low-humidity environment) at the time of the constant current of 3 μA stored in the memory 19 (S11).
If the detected voltage detected in S10 exceeds the threshold voltage value of +2200 V at the time of the constant current of 3 μA, the CPU determines that the abnormal discharge (predetermined discharge) does not occur (S12), and the value obtained by multiplying the environment coefficient and the value detected in S10 is determined as the transfer voltage value for the time of the image formation (S13). By taking into consideration the variation of the resistance value according to the sheet under the respective environments, the environment coefficient according to the respective environment is multiplied. If the detected voltage detected in S11 is equal to or lower than the threshold voltage value of +2200 V at the time of the constant current of 3 μA, the leakage due to the abnormal discharge (predetermined discharge) does not merely occur, but the current may be flowed due to the contact with the transfer roller 5, for example, according to the deformation of the shape of the separation charge removal needle 6. In this case, it is determined that the apparatus is abnormal (S14), and a service call is issued (S15).
(Effect of Control)
Next, the effect obtained by the above-described control will be described with reference to
As illustrated in
As a result, as illustrated in
On the other hand, in the apparatus where the embodiment is performed, in the temperature environment of 7.5° C. where the resistance value is high and, thus, the abnormal discharge more easily occurs than the temperature environment of 15° C., the applied voltage for the transfer roller 5 may be optimized according to whether or not the leakage detected in the time other than the image formation period actually occurs between the transfer roller 5 and the separation charge removal needle 6. For this reason, even in the environment temperature of 7.5° C., since partially slight deterioration in image quality may be observed due to the increase in resistance value of the transfer roller 5, it may be stated that there is almost no abnormality in image quality. In addition, even in a case where the environment temperature is changed from 7.5° to 15° C. due to the change in season, by performing the controlling of the transfer-roller applied current according to the embodiment, it is possible to allow the apparatus to automatically maintain the good image quality without intervention of an operator.
On the other hand, in the apparatus of Example 1 of the related art where any measures to the abnormal discharge are not taken, an abnormal image or damage to the apparatus occurs due to the abnormal discharge in the condition of 7.5° C. In addition, even in a case where the environment temperature is changed from 7.5° C. to 15° C., an abnormal image or damage to the apparatus occurs.
Example 2 of the related art is an “apparatus which avoids the abnormal discharge from a detection result of an atmospheric pressure”. In this apparatus, since the control is changed according to the level of the atmospheric pressure, even in the condition that the environment temperature is high and the resistance value of the transfer roller 5 is low, so that the abnormal discharge does not occur, under the environment where the atmospheric pressure is low, the control of avoiding the abnormal discharge is performed so as to decrease the transfer voltage. For this reason, the example cannot cope with the temperature of 15° C. where the abnormal discharge does not easily occur and a case where the temperature is changed from the temperature of 7.5° C. where the abnormal discharge easily occurs to the temperature of 15° C. where the abnormal discharge does not easily occur. In the example, it is determined based on only the atmospheric pressure that the abnormal discharge easily occurs, so that deterioration in image quality (transfer failure) occurs.
Example 3 of the related art is an “apparatus where a leakage detection circuit is added to a high-voltage board to detect the abnormal discharge”. In this apparatus, if the shapes of distal ends of individual electrodes, distances between electrodes, applied voltages, or the like are different, the degree of easiness of occurrence of the abnormal discharge is different, and thus, in many cases, the abnormal discharge cannot be accurately detected. Therefore, in the apparatus of Example 3 of the related art, even in the condition that the leakage detection circuit does not detect the abnormal discharge, the abnormal discharge occurs between the transfer roller 5 and the separation charge removal needle 6, so that deterioration in image quality (transfer failure) may occur.
On the contrary, in the apparatus of Example 3 of the related art, even in a case where the abnormal discharge does not occur between the transfer roller 5 and the separation charge removal needle 6, the control of avoiding discharge is performed by allowing the leakage detection circuit to determine that the abnormal discharge occurs, and thus, deterioration in image quality may occur due to a shortage of the transfer current. Actually, as illustrated in Example 3 of the related art in
Example 4 of the related art is an “apparatus where a service man manually sets up a pressure reduction mode”. In this apparatus, in a case where the image forming apparatus S is installed in a high-altitude area where the atmospheric pressure is low and, thus, the abnormal image occurs, the control (pressure reduction mode) of avoiding the abnormal discharge is manually set up. In this case, even in a case where the environment condition is changed due to the change in season to the condition where the abnormal discharge does not occur (for example, a case where the environment temperature is changed from 7.5° C. to 15° C.), if the pressure reduction mode is not released by the service man's manually setting up, an unnecessary deterioration in image quality (transfer failure) may occur.
Therefore, in this condition, as long as the service man does not repetitively set up or release the pressure reduction mode according to the change in air temperature, it is not possible to prevent the unnecessary deterioration in image quality. Example 4 of the related art in
Contrary to Examples 1 to 4 of the related art described heretofore, in the apparatus according to the embodiment, in a high-altitude area where the atmospheric pressure is low and there is a change in air temperature, without an operator such as a service man repetitively performing setting up or releasing the control (pressure reduction mode) of avoiding the abnormal discharge (predetermined discharge) which occurs due to the low atmospheric pressure, it is possible to prevent the occurrence of an unnecessary deterioration in image quality. In addition, when the abnormal discharge (predetermined discharge) occurs, it is possible to detect whether or not the abnormal discharge actually occurs between image forming components associated with the abnormal image (between the transfer roller and the separation charge removal needle or the like). Accordingly, without influence of the atmospheric pressure, it is possible to perform accurate detection according to a change in air temperature, so that it is possible to prevent the occurrence of deterioration in image quality (transfer failure).
In this manner, in the apparatus according to the embodiment, during a preparation operation before the image formation, by changing and flowing a transfer bias, a voltage where abnormal discharge is started is detected, and a voltage lower than the voltage where the abnormal discharge is started may be applied. For this reason, an appropriate applied voltage may be used without intervention of an operator while avoiding deterioration in image quality or damage to an electric element caused by the abnormal discharge, and it is possible to suppress transfer failure easily.
In addition, in the above-described embodiment, the voltage value detected when the transfer high-voltage circuit 21 flows a constant current is compared with the threshold voltage value of each environment, and the transfer voltage value applied in the image formation is determined. However, alternatively, a constant voltage circuit applies a constant voltage to the transfer roller 5, a current value flowed at this time is detected, and the determination unit compares the detected current value with a current value (threshold current value) flowing when the abnormal discharge of each environment does not occur, determines whether predetermined discharge occurs in the transfer unit.
In addition, instead of the environment detection sensor 18, an atmospheric pressure sensor may be arranged as the environment detection sensor. In a case where the transfer current is flowed based on an atmospheric pressure detected by the atmospheric pressure sensor, a threshold voltage where the abnormal discharge does not occur is defined in advance, and the threshold voltage at the atmospheric pressure is selected based on the atmospheric pressure detected by the atmospheric pressure sensor, so that the occurrence of the abnormal discharge may be determined.
In addition, in the embodiment, a DC voltage having a polarity opposite to that of the developer is applied from the transfer high-voltage circuit 21 of the high-voltage power supply unit to the transfer roller 5. However, the voltage applied to the transfer roller 5 is not limited to the DC voltage, but an AC voltage or a superposition of a DC voltage and an AC voltage may be applied.
Furthermore, in the embodiment, the occurrence of the abnormal discharge is determined based on the voltage value or the current value detected by the above-described detection unit, and in a case where the abnormal discharge occurs, the applied voltage value is allowed to be decreased. However, on the contrary, in a case where the occurrence of the abnormal discharge is not observed, the voltage value applied to the transfer roller 5 is allowed to be increased until the occurrence of the abnormal discharge is observed, and at a range where the occurrence of the abnormal discharge is not observed, the current value or the voltage value of the transfer unit at the time of the image formation may be determined. By increasing the voltage value, it is possible to improve the transfer function.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2014-112731, filed May 30, 2014, and No. 2015-101487 filed May 19, 2015, which are hereby incorporated by reference herein in their entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014-112731 | May 2014 | JP | national |
| 2015-101487 | May 2015 | JP | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 20120189330 | Kunimatsu | Jul 2012 | A1 |
| 20120243892 | Nakamura | Sep 2012 | A1 |
| Number | Date | Country |
|---|---|---|
| 5-88434 | Apr 1993 | JP |
| 10-097147 | Apr 1998 | JP |
| 2000-330401 | Nov 2000 | JP |
| 2010-48960 | Mar 2010 | JP |
| Entry |
|---|
| Office Action dated Feb. 13, 2018, in Japanese Patent Application No. 2015-101487. |
| Number | Date | Country | |
|---|---|---|---|
| 20150346683 A1 | Dec 2015 | US |
