Patent Grant
8185002
This application is based upon and claims priority from prior Japanese Patent Application No. 2005-374777 filed on Dec. 27, 2005, the entire contents of which are incorporated herein by reference.
The present invention relates to an image forming apparatus.
Conventionally, a technique for detecting the surface state of a belt has been offered in the field of the image forming apparatus. For example, a technique for reading a pattern image formed on the belt using a sensor was disclosed in JP-A-11-220586. In the conventional image forming apparatus, the information obtained by such reading is utilized for various kinds of control.
To detect the surface state of the belt at high precision, it is desirable to keep the belt in a stable state at the detection position. Therefore, with the technique of JP-A-11-220586, a rear face contact member for stabilizing the belt planarly is provided near an area for reading the pattern image. With this configuration, the surface state of the belt can be detected at high precision because the stable state is realized near the reading area. However, like the configuration as disclosed in JP-A-11-220586, where the tension is always strengthened in a predetermined area, a greater load is applied on the belt, possibly causing the belt to be elongated or reformed.
Aspects of the present invention provide a configuration capable of detecting the surface state of the belt at high precision while suppressing a load applied to the belt.
According to an aspect of the present invention, there is provided an image forming apparatus including: an image forming unit; an annular belt that moves circularly; a detection unit that detects a state of a surface of the belt; and a tension increase unit that increases a tension of the belt, at a detection position by the detection unit, when detection is performed by the detection unit, as compared with the tension of the belt before detection at the detection position is performed by the detection unit.
This color laser printer 1 is the color laser printer of tandem or transversely arranged type in which a plurality of process units 17 are disposed in parallel in the horizontal direction, and includes, within a main body casing 2, a paper feed unit 4 for feeding the paper 3 that is the recording medium, an image forming unit 5 for forming the image on the fed paper 3, and a paper exhausting unit 6 for exhausting the paper 3 on which the image is formed.
The main body casing 2 has a box shape, almost rectangular in side view, in which the upper side is opened, and is provided with a top cover 7 on its top. This top cover 7 is supported rotatably via a cover shaft 8 provided on the rear side of the main body casing 2 (in the following explanation, it is supposed that the left side in
The paper feed unit 4 includes a paper tray 9 provided on the bottom portion of the main body casing 2, a pickup roller 10 and a paper feed roller 11 provided upward on the fore side of the paper tray 9, a paper feed side U-shaped path 12 provided upward at the front of the paper feed roller 11, and a pair of conveying rollers 13 and a pair of registration rollers 14 provided in the middle of the paper feed side U-shaped path 12.
The paper tray 9 can be pulled out, and the sheets of paper 3 are stacked in this paper tray 9. The top paper 3 is picked up by the pickup roller 10, conveyed forward, and fed to the paper feed side U-shaped path 12 by the paper feed roller 11.
The paper feed side U-shaped path 12 is formed as a conveying passage of the paper 3 in the shape of a “U” character, in which its upstream end portion is adjacent to the paper feed roller 11 in the lower portion so that the paper 3 is fed forward, and its downstream end portion is adjacent to a conveying belt 38 in the upper portion, as will be described later, so that the paper 3 is conveyed backward.
And at the upstream end portion of the paper feed side U-shaped path 12, the paper 3 fed forward is conveyed by the conveying rollers 13 in the paper feed side U-shaped path 12 to reverse the conveying direction, registered by the registration rollers 14, and expelled backward by the registration rollers 14.
The image forming unit 5 includes a process unit 17, a transfer unit 18 and a fixing unit 19.
The process unit 17 is provided for each of a plurality of colors of toner. That is, the process unit 17 includes four units, including a yellow process unit 17Y, a magenta process unit 17M, a cyan process unit 17C and a black process unit 17K. The process units 17 are arranged successively in parallel so that they are spaced from each other from the front to the back, and overlapped in the horizontal direction.
Each process unit 17 includes a scanner unit 20 securely disposed in each process unit 17, and a process cartridge 21 removably mounted on each process unit 17.
The scanner unit 20 includes a laser light emitting unit (not shown), a polygon mirror 22, a lens 23 and a reflecting mirror 24. And in the scanner unit 20, a laser beam based on the image data emitted from the laser light emitting unit is reflected from the polygon mirror 22, passed through the lens 23, reflected from the reflecting mirror 24, and directed to a photosensitive drum 25, as will be described later.
Each process cartridge 21 is removably mounted along a direction inclined to the longitudinal direction and the vertical direction (thickness direction of the paper 3), namely, a direction inclined backward from upper to lower side (direction where the upper part is inclined forward), and includes the photosensitive drum 25, a Scorotron type changer unit 26, a developing roller 27 and a supply roller 28.
The photosensitive drum 25 is cylindrical, and includes a drum main body 29 formed of a positively charged photosensitive layer of which the top surface layer is made of polycarbonate, and a drum shaft 30 extending along an axial direction of the drum main body 29 in a shaft center of the drum main body 29. The drum main body 29 is provided rotatably around the drum shaft 30, which is supported on both side walls in the width direction (direction orthogonal to the longitudinal direction and the vertical direction, the same below) of a frame for the process cartridge 21. The photosensitive drum 25 is rotated and driven in the same direction (clockwise direction in the drawing) as the moving direction of the conveying belt 38 at the contact position (image forming position) with the conveying belt 38 in forming the image.
The Scorotron type charger unit 26 is the Scorotron type charger unit of positively charged type that has a wire and a grid, and generates a corona discharge. The Scorotron type charger unit is opposed to the photosensitive drum 25 and located behind the photosensitive drum 25 out of contact.
The developing roller 27 is opposed to the photosensitive drum 25 and disposed above the photosensitive drum 25, and pressed against the photosensitive drum 25. This developing roller 27 has a roller portion 32 of an elastic member made of conductive rubber material covered on a roller shaft 31 made of metal. Also, the roller shaft 31 is supported rotatably on both side walls in the width direction of the process cartridge 21.
The supply roller 28 is opposed to the developing roller 27 and disposed above the developing roller 27, and pressed against the developing roller 27. This supply roller 28 has a roller portion 34 made of conductive sponge material covered on a roller shaft 33 made of metal. Also, the roller shaft 33 is supported on both side walls in the width direction of the process cartridge 21.
Also, an upper portion of the process cartridge 21 is formed as a toner storage chamber 35 for storing the toner, in which the toner of each color is stored. That is, within the toner storage chamber 35, the positively charged, non-magnetic, one component polymerized toner is stored for each process unit 17, such as yellow toner for the yellow process unit 17Y, magenta toner for the magenta process unit 17M, cyan toner for the cyan process unit 17C and black toner for the black process unit 17K.
In each process unit 17, the toner of each color stored in each toner storage chamber 35 is supplied to the supply roller 28 and supplied to the developing roller 27 along with the rotation of the supply roller 28 in the image forming operation. At this time, the toner is positively charged frictionally between the supply roller 28 and the developing roller 27 to which a developing bias is applied.
On the other hand, the Scorotron type charger unit 26 generates a corona discharge by the application of a charging bias to positively charge the surface of the photosensitive drum 25 uniformly. The surface of the photosensitive drum 25 is positively charged uniformly by the Scorotron type charger unit 26 along with the rotation of the photosensitive drum 25, and exposed by fast scanning of laser beam from the scanner unit 20 to form an electrostatic latent image corresponding to the image to be formed on the paper 3.
If the photosensitive drum 25 is further rotated, the positively charged toner carried on the surface of the developing roller 27 confronts and contacts the photosensitive drum 25 along with the rotation of the developing roller 27, and is then supplied to the electrostatic latent image formed on the surface of the photosensitive drum 25, namely, an exposed portion having a lower potential due to exposure to the laser beam on the uniformly, positively charged surface of the photosensitive drum 25. Thereby, the electrostatic latent image on the photosensitive drum 25 is visualized, so that a toner image for each color by reversal development is carried on the surface of the photosensitive drum 25.
The transfer unit 18 is disposed along the longitudinal direction above the paper feed unit 4 and below the process unit 17 within the main body casing 2, and includes a drive roller 36, a tension roller 37, a conveying belt 38, a transfer roller 39 and a belt cleaning unit 40.
The drive roller 36 is rotated and driven in a reverse direction (counterclockwise in the drawing) to the rotation direction of the photosensitive drum 25 by a motor M2 as conceptually shown in
The tension roller 37 is rotated following the conveying belt in the same direction (counterclockwise in the drawing) as the moving direction of the conveying belt 38 at a contact portion with the conveying belt 38, while the drive roller 36 is rotated and driven.
The conveying belt 38 is an annular belt, and formed of conductive resin such as polycarbonate or polyimide with conductive particles such as carbon dispersed. This conveying belt 38 is wound over the drive roller 36 and the tension roller 37. The tension roller 37 is driven by the driving of the drive roller 36, and the conveying belt 38 is circularly moved between the drive roller 36 and the tension roller 37 to be rotated in the same direction as the photosensitive drum 25 at the image forming position of confronting and contacting the photosensitive drum 25 of each process unit 17. At this time, the drive roller 36 is disposed on the downstream side and the tension roller 37 is disposed on the upstream side in the moving direction of the conveying belt 38 at the contact position with the photosensitive drum 25, thereby pulling an upper portion of the conveying belt 38 opposed to the photosensitive drum 25, and preventing occurrence of a looseness in the upper portion. Therefore, the paper 3 can be conveyed by the conveying belt 38 accurately.
In addition to the drive roller 36, the tension roller 37, and the conveying belt 38, the transfer unit 18, the pickup roller 10, the paper feed roller 11, the rear conveying roller 13, and one pair of registration rollers 14 are integrally held on a belt unit frame 61, thereby constituting a belt unit 60 that can be removed in the horizontal direction from the front side of the main body casing 2.
Also, each transfer roller 39 is opposed via the conveying belt 38 to the photosensitive drum 25 of the corresponding process unit 17 inside the conveying belt 38 wound between the drive roller 36 and the tension roller 37. This transfer roller 39 has a roller shaft 41 made of metal covered with a roller portion 42 of an elastic member made of conductive rubber material. Also, the transfer roller 39 is borne by the bearings (not shown) having conductivity at both ends of the roller shaft 41.
A transfer bias line is electrically connected to each bearing, whereby a transfer bias is applied via the bearing from the transfer bias line to the transfer roller 39 at the time of image forming.
Referring to
That is, the yellow toner image carried on the surface of the photosensitive drum 25 in the yellow process unit 17Y is transferred on the paper 3. Then, the magenta toner image carried on the surface of the photosensitive drum 25 in the magenta process unit 17M is transferred and superposed on the paper 3 where the yellow toner image is already transferred. By the same operation, the cyan toner image carried on the surface of the photosensitive drum 25 in the cyan process unit 17C and the black toner image carried on the surface of the photosensitive drum 25 in the black process unit 17K are transferred and superposed. As a result, the color image is formed on the paper 3.
The belt cleaning unit 40 includes a cleaning box 46 and a cleaning roller 47. The cleaning box 46 is formed with an opening portion in a part on the side opposed to the conveying belt 38, and its inner space is formed as a residual storage unit for storing the adherents removed from the conveying belt 38.
The cleaning roller 47 consists of a roller covered with a cylindrical sponge around the outer circumference of a metallic shaft, and is supported rotatably in an opening portion of the cleaning box 46 to be in contact with an outer face 38b on the lower portion of the conveying belt 38. This cleaning roller 47 is driven to apply a force in a direction opposite to the moving direction of the conveying belt 38 on the contact portion with the conveying belt 38 during the cleaning operation. That is, the cleaning roller 47 is rotated and driven by the motor M1 so that a peripheral face 47A in contact with the conveying belt 38 may be moved in a direction opposite to the moving direction of the conveying belt 38 at the contact position with the conveying belt 38. A cleaning bias from a bias line, not shown, is applied to this cleaning roller 47.
In this configuration, the adherents such as the toner adhering to the conveying belt 38 due to contact with the photosensitive drum 25 or the paper powder adhering to the conveying belt 38 due to contact with the paper 3 are captured by the cleaning roller 47, when placed opposite the cleaning roller 47 during the movement of the conveying belt 38. And the captured adherents are scraped away from the cleaning roller 47 within the cleaning box 46, and stored in the residual storage unit within the cleaning box 46.
Moreover, a counter roller 110 is provided to be opposed to the cleaning roller 47 via the conveying belt 38. This counter roller 110 carries the belt together with the cleaning roller 47. In this aspect, the counter roller 110 is supported rotatably at a predetermined position of the frame for the conveying belt 38, to entrain the conveying belt by contact with the conveying belt 38.
The fixing unit 19 is disposed in the rear of the transfer unit 18. This fixing unit 19 includes a heating roller 48 and a pressure roller 49.
The heating roller 48 is a metallic element tube formed with a surface lubricant layer on its surface and internally has a halogen lamp along its axial direction. The surface of the heating roller 48 is heated up to a fixing temperature by the halogen lamp. Also, the pressure roller 49 is provided to press the heating roller 48.
The color image transferred on the paper 3 is then conveyed to the fixing unit 19, and thermally fixed while the paper 3 is passed between the heating roller 48 and the pressure roller 49.
The paper exhausting unit 6 includes a paper exhausting side U-shaped path 50, the paper exhausting rollers 51 and a paper output tray 52.
The paper exhausting side U-shaped path 50 is formed as a conveying path of the paper 3 in the shape of a “U” character, in which its upstream end portion is adjacent to the fixing unit 19 in the lower portion, so that the paper 3 is fed backward, and its downstream end portion is adjacent to the paper output tray 52 in the upper portion, so that the paper 3 is exhausted forward.
One pair of paper exhausting rollers 51 is provided at an end portion on the downstream side of the paper exhausting side U-shaped path 50.
The paper output tray 52 is formed as an inclined wall inclined downward from the front to the back on the upper face of the main body casing 2.
The paper conveyed from the fixing unit 19 is fed backward to the upstream end of the paper exhausting side U-shaped path 50 to reverse the conveying direction within the paper exhausting side U-shaped path 50, and exhausted forward onto the paper output tray 52 by the paper exhausting rollers 51.
The electrical configuration of the laser printer 1 will be described below.
The laser printer 1 has a control unit 90 for controlling each component using a control unit 95 including a CPU 91, a ROM 92, a RAM 93, and an ASIC (Application Specific Integrated Circuit) as shown in
The ROM 92 and the RAM 93 are connected to the CPU 91, which controls each component via the control unit 95 in accordance with a procedure stored in the ROM 92, while storing the processing result in the RAM 93.
The main motor 96 rotates the conveying belt 38. Also, the scanner motor 97 rotates the polygon mirror 22 within the scanner unit 20.
The CPU 91 controls the driving of the main motor 96 and the scanner motor 97 based on a program stored beforehand in the ROM 92.
The control unit 95 controls the image forming unit 5 in accordance with a command from the CPU 91. Specifically, it makes the exposure control for exposing the surface of the photosensitive drum 25 with each part making up the scanner unit 20, and the transfer bias control in transferring the toner onto the paper 3.
Also, the control unit 90 is provided with a network interface (network I/F) 94 for connecting to an external apparatus such as a personal computer.
The motor M1 consists of a DC motor, for example, and is controlled for the driving by the control unit 95 and a drive circuit, not shown, to be rotatable in both directions (see F1 and F2 in
The outline of the feature configuration of this aspect will be described below.
As shown in
In the laser printer 1, the tension of the conveying belt 38 is increased at a detection position P1 of the sensor 100 (to which the sensor 100 is opposed) as compared with before detection, when the sensor 100 senses the surface darkness of the conveying belt 38. In this aspect, a tension increase unit includes the CPU 91, the motor M1 and the cleaning roller 47. Specifically, when the pattern image is detected by the sensor 100, or when the substrate darkness on the belt is detected by the sensor 100, the tension of the belt at the detection position is increased as compared with before detection. In the following, the control configuration for the image formation, and further the configuration for increasing the tension will be described in detail.
First of all, a normal image forming process will be described below.
As shown in a flowchart of
The paper feed operation is performed by the paper feed unit 4 at S20. Then, the image forming operation is performed by the image forming unit 5 at S30. Thereafter, if the paper exhausted onto the paper output tray 52 is detected by a sensor, not shown, the operation branches to Yes at S40 to go to a normal image forming end process at S60. On the other hand, if the paper exhausted is not confirmed within a predetermined period, the operation branches to No at S40 to display an error message for paper jam at S50, and then advances to the normal image forming process at S60. This normal image forming end process involves stopping all of the conveying belt 38, the photosensitive drum 25, the developing roller 27, the cleaning roller 47, and the fixing rollers (heating roller 48, pressure roller 49) which start to be driven in the normal image forming start process at S10. They may be stopped in sequence or in parallel.
A patch concentration measurement process will be described below.
If the patch concentration measurement process is executed, first of all, a patch concentration measurement start process is performed at S100. The patch concentration measurement start process at S100, which is the same as the normal image forming start process at S10 in
Thereafter, a patch P (corresponding to one example of the pattern image) as illustrated in
The example of patch is not limited to the mark group for each color as shown in
The formed patch P (
In this aspect, after the cleaning roller 47 starts to be driven in the normal direction at S100, the driving in the normal direction is maintained, and the detection is made by the sensor 100 in this state. That is, while the concentration of the patch P is being detected by the sensor 100, the resistance force of the cleaning roller 47 against the circulating movement of the conveying belt 38 is decreased as compared with before detection (more particularly before starting to drive the cleaning roller 47 in the normal direction), so that the tension of the conveying belt 38 at the detection position P1 is increased.
If the concentration detection of the patch P is ended, the operation branches to Yes at S140. At S150, the cleaning roller 47 is driven in a reverse direction (direction of the arrow F2 in
If the cleaning of the patch P is ended, the operation branches to Yes at S160, whereby the cleaning roller 47 is driven in the normal direction. The driving in the normal direction is a preparation process for detecting the next patch P. If the next patch P does not exist, the operation branches to Yes at S180 to go to the patch concentration measurement end process at S190. If the next patch P exists, the operation branches to No at S180, whereby the process from S120 to S170 is repeated again. Since the cleaning roller 47 starts to be driven in the normal direction at S170, if the next patch P exists, the resistance force of the cleaning roller 47 against the circulating movement of the conveying belt 38 is decreased as compared with before detection (before starting to drive the cleaning roller 47 in the normal direction) when the concentration of the next patch P is detected by the sensor 100, so that the tension of the conveying belt 38 at the detection position P1 is increased. Accordingly, the concentration detection of the next patch P is made at high precision.
The patch concentration measurement end process at S190 involves stopping the photosensitive drum 25, the developing roller 27, the cleaning roller 47 and the conveying belt 38 which start to be driven in the patch concentration measurement start process at S110. They may be stopped in sequence or in parallel.
In this aspect, the patches P (pattern images) having the length L2 shorter than the length L1 between the detection position P1 (
Also, when the plurality of patches P are formed in the image forming unit 5, the preceding patches PY and the succeeding patches PM are spaced by a clearance L3 larger than the length L1 between the detection position P1 and the cleaning position P2, and formed on the conveying belt 38, as shown in
In this aspect, since the image forming unit 5 forms the patches P separately, spaced by the clearance L3 larger than the length L1 (
Referring to a flowchart of
As shown in
As described above, in this aspect, when the surface state of the belt is detected by the sensor 100, the tension of the conveying belt 38 at the detection position P1 can be increased to stabilize the conveying belt 38, whereby the surface state of the conveying belt 38 is detected at high precision. Also, the tension of the conveying belt 38 is not always increased, but the tension is controlled to be weakened for a certain period, so that the load on the conveying belt 38 is suppressed, and the elongation or reform of the conveying belt 38 is effectively suppressed.
Since the tension of the conveying belt 38 can be increased when employing the cleaning roller 47, it is unnecessary to provide any special components to increase the tension of the conveying belt 38, whereby the detection at high precision can be made with lower costs.
Also, in detecting the patch, the rotational speed of the cleaning roller 47 in the forward direction for delivering the conveying belt 38 is relatively increased as compared with before detection (more particularly the cleaning roller 47 is driven in the forward direction for delivering the conveying belt 38 from the stopped state (see S100 in
In this aspect, the conveying belt 38 is stretched around two rollers to make up two planes 38A and 38B, as shown in
Referring to
In the above aspect, the tension of the conveying belt 38 is increased by relatively changing the rotational speed of the cleaning roller 47 in the forward direction. On the other hand, in this aspect, the cleaning roller 47 can be contacted with or not-contacted with the conveying belt 38 to increase the tension of the conveying belt 38. Since the configuration other than the cleaning unit 40 is the same as in the above aspect, the detailed explanation of the configuration other than the cleaning unit 40 is omitted.
As shown in
One example of a driving configuration is shown in
The present invention is not limited to the aspects as described above and shown in the drawings, but the following aspects may also fall within the technical scope of the invention, and various modifications may be made without departing from the spirit or scope of the invention.
While the tension of the belt is increased by the cleaning roller 47 in the above aspects, a tension increase unit may be implemented by the drive roller 36. For example, the sensor 100 is disposed opposite to a portion from the drive roller 36 to the tension roller 37 in the circulating direction of the conveying belt 38, as in the above aspects, and the drive roller 36 is controlled so that the rotational speed of the drive roller 36 is decreased from the first rotational speed before detection to the second rotational speed smaller than the first rotational speed, thereby increasing the tension of the conveying belt 38 as compared with before detection. As an example, the rotational speed may be decreased by controlling the current value to the main motor 96 under the control of the CPU 91, in which the CPU 91, the main motor 96 and the drive roller 36 corresponds to the tension increase unit. In this case, the configuration for increasing the tension of the belt can be simply implemented without providing a special component such as the tension increase unit, whereby the detection can be made at high precision with lower costs.
The “image forming apparatus” of the invention is not only the printing apparatus such as the printer (e.g., laser printer) but also may be a facsimile apparatus or a multi-function apparatus having the print function and the scanner function. Also, it is not limited to the tandem type including an image carrier for each developing roller 27, as in the above aspects, but may be a transfer type in which each developing roller forms the developer image on the common image carrier, an intermediate transfer type, or a single path type.
The belt as defined in the present invention is not limited to the conveying belt as in the above aspects. For example, when the image forming apparatus is constructed as a multiple developing type apparatus (single path type or multi-rotation type), the “photosensitive belt” on which the electrostatic latent image is formed by exposure may be the “belt” of the invention. Also, when the image forming apparatus is constructed as an intermediate transfer type apparatus, an “intermediate transfer belt” filling the intermediate role to transfer the developer image carried on the photosensitive drum onto the recording medium may be the “belt” of the invention.
While in the above aspects, the resistance force is adjusted by controlling the rotational speed or the contact or not-contact of the cleaning roller, the resistance force may be adjusted by controlling the contact force of the cleaning member with the belt. For example, the resistance force may be adjusted by strongly pressing the cleaning member against the belt during the cleaning, but weakly pressing it at the time of detection.
While in the above aspects, the cleaning roller is exemplified as the cleaning member, the cleaning member may have the ability of wiping or scraping away the foreign matter on the belt (e.g., cleaning blade constructed like a blade). When the cleaning blade is employed, the resistance force may be adjusted by contact or not-contact of the cleaning blade, or the resistance force may be adjusted by controlling the contact force of the cleaning blade with the belt.
While in the above aspects, the cleaning member is constituted by the cylindrical cleaning roller, the cleaning member may be constituted of a rotatable brush member.
While in the above aspect, the rotational speed of the cleaning roller 47 in the forward direction is relatively increased by rotating the cleaning roller 47 in the normal rotation direction (forward direction) from the stopped state, or by rotating it from the reverse rotation direction to the normal rotation direction, the following method may be adopted for decreasing the resistance force by relatively increasing the rotational speed of the cleaning roller 47 in the forward direction. For example, the resistance force may be decreased by changing the cleaning roller from a predetermined rotational speed (first forward rotational speed) to a second forward rotational speed greater than the first rotational speed in a state where the cleaning roller 47 is rotated in the normal rotation direction (forward direction) for delivering the conveying belt 38. Also, the resistance force may be decreased by changing the cleaning roller from a predetermined rotational speed (first reverse rotational speed) to the second reverse rotational speed smaller than the first rotational speed in a state where the cleaning roller 47 is rotated in a reverse direction to the normal rotation direction (forward direction) for delivering the conveying belt 38.
While in the above aspects the patch for concentration measurement is exemplified as the “pattern image”, the patch is not limited to concentration measurement. For example, the patch may be a mark for measuring the movement amount of the belt, or a registration mark formed to detect the image formed position for each color.
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