Patent Grant
6961526
1. Field of the Invention
The present invention relates to an image forming apparatus, such as a printer and a copying machine, for forming an image on a recording medium.
2. Description of the Related Art
Hitherto, an electrophotographic image forming apparatus is known in which an electrostatic latent image is formed on an electrophotographic photoconductor (referred to simply as a “photoconductor” hereinafter), serving as an image carrier, with exposure of, e.g., a laser beam emitted in response to an image signal, the electrostatic latent image is visualized into a developer (toner) image using a developer, and a hard image is obtained by transferring the toner image onto a transfer material and then fusing it.
Also, an electrophotographic image forming apparatus for forming a color image is known in which developer (toner) images of multiple colors formed on a photoconductor are successively transferred onto a recording medium (also referred to as a “transfer material” hereinafter), or in which developer (toner) images of multiple colors formed on a photoconductor are primary-transferred onto an intermediate transfer member and then secondary-transferred onto a transfer material, whereby a color toner image is formed on the transfer material.
In an electrophotographic image forming apparatus, if variations occur in performance of apparatus components with changes of environment around the apparatus and use of the apparatus for a long period, the density of a toner image formed on a transfer material by the image forming apparatus also varies. In an electrophotographic image forming apparatus for forming a color image, particularly, there is a risk that a color balance is lost even with a slight variation in density of the toner image. It is hence desired to keep constant the image density and gradation characteristics at all times regardless of variations in performance of the apparatus components.
In an image forming apparatus for forming a color image, therefore, a method for keeping constant the image density and gradation characteristics (i.e., color balance) at all times is proposed and comprises, for example, the step of changing process conditions such as an amount of laser exposure and a development bias, or adjusting the compensation factors set in a lookup table (LUT) which is used to modify an image signal for forming an electrostatic latent image on a photoconductor with the laser exposure, depending on changes of environment (e.g., absolute temperature) around the apparatus and variations in performance of the apparatus components.
Also, as a method for ensuring constant the image density and gradation characteristics in spite of variations in performance of the components of the image forming apparatus, it is conceivable to form a pattern of a reference developer image (referred to as a “toner patch” hereinafter) for density detection on a photoconductor or an intermediate transfer member, and to detect the density of the toner patch with a photosensor. That method enables the image density and gradation characteristics (i.e., color balance) to be kept constant at all times by changing process conditions such as an amount of laser exposure and a development bias, or by modifying an image signal based on a lookup table (LUT) which is used to modify the image signal for forming an electrostatic latent image on a photoconductor with the laser exposure, in accordance with a result detected by a photosensor.
In the above-mentioned toner image density control using a photosensor, however, the density is detected using a toner patch formed on the photoconductor or the intermediate transfer member, and the control is not intended to compensate for a change in image color balance caused by transferring and fusing a toner image onto a transfer material. Further, it is known that the image color balance is also changed depending on not only the efficiency in transfer of a toner image onto a transfer material, but also heat and pressure applied during the fusing.
In the view of the state of the art mentioned above, it is an object of the present invention to provide an improved image forming apparatus.
Another object of the present invention is to provide an image forming apparatus in which, by detecting an image formed on a recording medium, at least one of the density and chromaticity of the image can be properly controlled.
To achieve the above objects, the present invention provides an image forming apparatus comprising an image forming unit for forming a toner image on an image carrier; a transfer unit for transferring the toner image formed by the image forming unit onto a transfer material in a transfer position; a fusing unit for fusing the toner image transferred by the transfer unit on the transfer material; a feed-direction changing unit for changing over a feed direction of the transfer material so that the transfer material having the toner image fused by the fusing unit is reversed and fed to the transfer position; a detecting unit for detecting, in a predetermined detecting position, the toner image fused on the transfer material by the fusing unit, the predetermined detecting position being a certain position near the transfer position in the middle of a feed path of the transfer material within a region after the feed direction of the transfer material has been changed over by the feed-direction changing unit; and a control unit for controlling the image forming unit based on a result detected by the detecting unit.
Further objects, features and advantages of the present invention will become apparent from the following description of the preferred embodiments with reference to the attached drawings.
An image forming apparatus according to the present invention will be described below with reference to the drawings.
The image forming apparatus 100 shown in
An image forming section A has stations Py, Pm, Pc and Pk arranged in tandem corresponding to the number of colors (four, i.e., yellow, magenta, cyan and black) of toners used in development to form a superimposed color toner image. Each station comprises a photoconductor drum 23 (23Y, 23M, 23C or 23K) serving as an image carrier in the form of a drum, a primary charging unit 24 (24Y, 24M, 24C or 24K), a developing unit 25 (25Y, 25M, 25C or 25K), a primary transfer unit 26 (26Y, 26M, 26C or 26K), a scanner section 27 (27Y, 27M, 27C or 27K), and a developer resupply container (toner cartridge) 28 (28Y, 28M, 28C or 28K). The image forming section A also includes the intermediate transfer member 12 serving as an image carrier, which is moved relative to each of the stations Py, Pm, Pc and Pk. The image forming apparatus 100 further includes sheet feed sections 11, a secondary transfer roller 13 serving as a secondary transfer unit, a fusing unit 14, a cleaning unit 32, and so on.
In addition, each of the photoconductor drums 23Y, 23M, 23C and 23K is constituted by coating an organic photoconductive layer on an outer circumferential surface of an aluminum cylinder, and is rotated by driving forces transmitted from a drive motor M (FIG. 6). The drive motor M rotates the photoconductor drums 23Y, 23M, 23C or 23K in a direction of arrow in
The image forming apparatus 100 includes four injection chargers 24Y, 24M, 24C and 24K which are provided respectively in the stations Py, Pm, Pc and Pk and serve as the primary charging units 24 for electrically charging the photoconductor drums 23Y, 23M, 23C and 23K. The injection chargers 24Y, 24M, 24C and 24K have, as charging members, charging sleeves 24YS, 24MS, 24CS and 24KS.
In the image forming apparatus 100, exposure beams are irradiated from the scanner sections 27Y, 27M, 27C and 27K to the photoconductor drums 23Y, 23M, 23C and 23K for selective exposure of the surfaces of the photoconductor drums 23Y, 23M, 23C and 23K which have been uniformly charged. Electrostatic latent images are thereby formed on the surfaces of the photoconductor drums 23Y, 23M, 23C and 23K corresponding to respective image signals.
The image forming apparatus 100 includes four developing units 25Y, 25M, 25C and 25K for development in respective colors, i.e., yellow (Y), magenta (M), cyan (C) and black (B), which are provided respectively in the stations Py, Pm, Pc and Pk and serve as the developing units for visualizing the respective electrostatic latent images formed on the photoconductor drums 23Y, 23M, 23C and 23K. The developing units 25Y, 25M, 25C and 25K include developing sleeves 25YS, 25MS, 25CS and 25KS that serve as developing members (developer carriers) for applying developers to the photoconductor drums 23Y, 23M, 23C and 23K and for supplying the toners as the developers. The developing units 25Y, 25M, 25C and 25K are detachably attached to the apparatus body.
Further, in the image forming apparatus 100, an endless belt running over a plurality of rollers is used as the intermediate transfer member 12. The intermediate transfer member 12 is in contact with the photoconductor drums 23Y, 23M, 23C and 23K and is rotated (circulated) in a direction of arrow in
In the image forming apparatus 100, when the multi-color toner image is transferred onto the transfer material 22, the secondary transfer roller 13 is brought into contact with the transfer material 22 in a position as indicated by a solid line 13a in
A fusing section constituting the fusing unit 14 fuses, for fixation under heating, the multi-color toner image having been transferred onto the transfer material 22 while feeding the transfer material 22. As shown in
In the image forming apparatus 100, after fusing the toner image on the transfer material 22, the transfer material 22 is advanced to a sheet ejection section 19 and the image forming operation is brought to an end.
The cleaning unit 32 serves to clean the toner remaining on the intermediate transfer member 12 after the toner image has been transferred from the intermediate transfer member 12 onto the transfer material 22. In the cleaning unit 32, waste toners left after transferring, onto the transfer material 22, the four-color toner images formed on the intermediate transfer member 12 are stored in a cleaner container.
In the image forming apparatus 100 of
The light receiving device 42 shown in
Density control of the image forming apparatus 100 can be performed based on a result of density detection using the photosensor 40 for density control, shown in
However, the density control using the photosensor 40 for density control implies control in which the toner density patch pattern 44 is formed on the intermediate transfer member 12 of the image forming apparatus 100 and then detected. In the image forming apparatus 100, the toner images formed on the intermediate transfer member 12 are transferred onto the transfer material 22 and fused in the fusing unit 14. Therefore, a color balance of the toner image fused and fixed to the transfer material 22 may vary depending on the transfer efficiency in the transfer process and the heating and/or pressing condition during the fusing.
In view of the above, the present invention intends to propose a method for keeping constant the density and gradation characteristics (i.e., color balance) of the toner image after being fused on the transfer material 22, by detecting the density or chromaticity of the toner image on the transfer material 22 after transferring and fusing the toner image onto the transfer material 22, and then changing process conditions such as an amount of laser exposure and a development bias, or modifying an image signal based on a lookup table (LUT) which is used to modify the image signal for forming the electrostatic latent image on the photoconductor drum 23 with the laser exposure.
A method for detecting the density or chromaticity of the toner image on the transfer material 22 and properly maintaining the density and gradation characteristics (i.e., color balance) of the toner image, according to a first embodiment of the present invention, will be described with reference to the drawings.
As shown in
Also, the image forming apparatus 100 includes a duplex flapper 16 as a means for changing over a feed path of the transfer material 22 after having passed the fusing unit 14. When the duplex flapper 16 is in a downward inclined position as indicated by solid lines 16d in
In the first embodiment, the construction and operation of an image forming section A for forming toner images on the intermediate transfer member 12 with a plurality of image forming units (stations P) and transferring the toner images onto the transfer material 22, and the constructions and operations of a sheet feed section 11, a secondary transfer roller 13 and a fusing unit 14 are the same as those in the image forming apparatus 100 described above with reference to FIG. 1. Therefore, the components having the same functions and constructions are denoted by the same characters and are not described in detail here.
In the case of employing the color sensor 50 described above, if the color sensor 50 for detecting the density or chromaticity of the toner patch pattern 60 formed on the transfer material 22 after being transferred and fused is disposed on the feed path of the transfer material 22 immediately after (downstream in the feed direction) the fusing unit 14 for the purpose of detecting the density or chromaticity of the toner image on the transfer material 22 after being transferred and fused onto the transfer material 22, an ambient region of the fusing unit 14 surrounding the color sensor 50 is affected by the heat radiated from the fusing unit 14. In other words, the vicinity of the fusing unit 14 is heated to such an extent that the result of detecting the density or chromaticity of the toner patch pattern 60 may vary because of deformations of the optical elements, such as lenses, and the sensor holder constituting the color sensor 50, as well as changes in spectrum and amount of the light emitted from the white LED 51 and changes in spectroscopic sensitivity characteristics of the charge accumulated sensor 52 with the RGB on-chip filter.
Taking into account the above-described drawback, as shown in
An image processing control section (image processing controller) 101 receives an image signal from an external host, such as a personal computer, connected to the apparatus body in a communicable manner, or from a document reader (not shown) separately provided in association with the image forming apparatus 100, and also transmits a signal for image formation to a image forming control section 103 (described later).
An LUT 102 is a table for converting the image signal and is employed to modify an image signal received by the image processing control section 101 into an image signal for forming the electrostatic latent image on the photoconductor drum 23 with the laser exposure.
The image forming control section (image forming controller) 103 controls the various components of the image forming apparatus 100. More specifically, the image forming control section 103 controls the image forming section A, which is made up of the primary charging unit 24, the developing unit 25, the primary transfer unit 26, the scanner section 27, the fusing unit 14, the photosensor 40 and the color sensor 50. Information regarding the density or chromaticity detected by the color sensor 50 is input to the image forming control section 103 and further input, through the image forming control section 103, to the image processing control section 101 to be used therein as information for adjusting the LUT 102 that is used to modify the image signal. Further, the image forming control section 103 controls the drive motor M for driving the photoconductor drum 23, the intermediate transfer member 12, the fusing roller 15, and feed rollers (not shown) arranged in the sheet ejecting section 19, the switchback flapper 20, the duplex flapper 16 and the switchback mechanism 17, along the sheet feed path. The drive motor M may be constituted as a single motor in common to the various sections and its driving forces may be transmitted in a properly switched manner. Alternatively, a plurality of drive motors may be disposed in the various sections and controlled independently of one another.
The operation of the image forming apparatus 100 according to the first embodiment will be described with reference to a flowchart of FIG. 7.
When the image forming control section 103 receives a control command instructing control of the density or chromaticity from the image processing control section 101 in step S701, it starts feed of the transfer material 22 from the sheet feed section 11 in step S702.
In step S703, the image forming control section 103 executes the control process for transferring the toner image onto the obverse (first) side of the transfer material 22 with the action of the secondary transfer roller 13 as described above.
In step S704, the image forming control section 103 executes the control process for feeding the transfer material 22 to the fusing unit 14 and then fusing and fixing the toner image to the transfer material 22.
In step S705, the image forming control section 103 controls the duplex flapper 16 to take a position (indicated by 16u in
In step S706, the image forming control section 103 executes the control process for feeding the transfer material 22, which has been reversed through the switchback mechanism 17, in the duplex unit 18.
In step S707, the color sensor 50 detects the toner patch pattern 60 in a position that is set for the detection by the color sensor 50 which exists in the middle of the feed path of the transfer material 22 toward the secondary transfer section T2. Also, the image processing control section 101 adjusts the LUT 102 based on the result received from the color sensor 50 through the image forming control section 103.
In step S708, the image forming control section 103 controls the duplex flapper 16 to take a position (indicated by 16d in
The color image compensation control executed by the image forming control section 103 and the image processing control section 101 in step S707 will now be described with reference to
First, the toner patch pattern 60 shown in
The process gray gradation patch 62a is formed to have the same chromaticity as that of the monochrome gray gradation patch 61a, and these patches are successively formed in the feed direction of the transfer material 22 (direction of arrow B in FIG. 5). Likewise, the process gray gradation patch 62b and the monochrome gray gradation patch 61b, the process gray gradation patch 62c and the monochrome gray gradation patch 61c, the process gray gradation patch 62d and the monochrome gray gradation patch 61d, as well as the process gray gradation patch 62e and the monochrome gray gradation patch 61e are also formed to have the same chromaticity for each pair. Then, the monochrome gray gradation patches 61 (61a, 61b, 61c, 61d and 61e) have different levels of gradation (density) that are stepwisely increased in the feed direction as shown in
Although it is desired, as described above, that the amounts of the mixed toners of three YMC colors are set to make each pair of the monochrome gray gradation patch 61 and the process gray gradation patch 62 have the same chromaticity, the chromaticity of the monochrome gray gradation patch 61 and the chromaticity of the process gray gradation patch 62 actually formed on the transfer material 22 are not always coincident with each other. In the image forming apparatus 100, therefore, the amounts of the mixed toners of three YMC colors, i.e., the respective densities of the color toners, are properly adjusted based on the results obtained by the color sensor 50 detecting the monochrome gray gradation patches 61 and the process gray gradation patches 62 so that each pair of the monochrome gray gradation patch 61 and the process gray gradation patch 62 have the same chromaticity.
In step S801, the color sensor 50 detects the chromaticity of the monochrome gray gradation patch 61a on the transfer material 22 that has passed the fusing unit 14 and has the toner patch pattern 60 for chromaticity control.
In step S802, the color sensor 50 detects the chromaticity of the process gray gradation patch 62a on the transfer material 22.
In step S803, based on the results detected in steps S801 and S802, the image forming control section 103 compares the chromaticity of the monochrome gray gradation patch 61a with the chromaticity of the process gray gradation patch 62a, and determines whether the chromaticity difference between the patches 61a and 62a is within a predetermined value (e.g., within DE3 representing the chromati city difference allowable for the human perception).
If it is determined in step S803 that the chromaticity difference between the monochrome gray gradation patch 61a and the process gray gradation patch 62a is within the predetermined value, the image processing control section 101 determines in step S804 that the process gray gradation patch 62a is achromatic and has the same gradation (density) as that of the process gray gradation patch 62a. Then, the process flow advances to the next step without adjusting the LUT 102.
On the other hand, if it is determined in step S803 that the chromaticity difference between the monochrome gray gradation patch 61a and the process gray gradation patch 62a is not within the predetermined value, the image processing control section 101 determines in step S805 that the process gray gradation patch 62a is chromatic or has a different gradation (density) from that of the process gray gradation patch 62a. Then, in step S806, the image forming apparatus 100 adjusts the compensation factors in the LUT 102 so as to adjust the amounts of the mixed toners of three colors, i.e., yellow (Y), magenta (M) and cyan (C), forming the process gray gradation patch 62a. The adjustment of the LUT 102 is described later in detail with reference to FIG. 9.
In step S807, the image forming control section 103 determines whether there remain the monochrome gray gradation patch 61 and the process gray gradation patch 62 to be next detected by the color sensor 50. If the determination result is “YES”, the process flow returns to step S801 and executes the subsequent steps.
By repeating the steps described above, the color sensor 50 detects, subsequent to the pair of the monochrome gray gradation patch 61a and the process gray gradation patch 62a, the pairs of 61b and 62b, 61c and 62c, 61d and 62d, as well as 61e and 62e. Correspondingly, the image processing control section 101 adjusts the LUT 102 for each of plural gradations.
In the above description, each time when the color sensor 50 detects one pair of the monochrome gray gradation patch 61 and the process gray gradation patch 62, the image processing control section 101 executes the compensation process. However, it is also possible to first detect the chromaticity of each of all the patches 61 (61a, 61b, 61c, 61d and 61e) and 62 (62a, 62b, 62c, 62d and 62e), and to determine in concentrated fashion whether the respective process gray gradation patches 62 are each achromatic and have the same gradation (density).
Also, in step S803, the chromaticity of the process gray gradation patch 62 may be compared with the chromaticity of each of all the monochrome gray gradation patches 61 (61a, 61b, 61c, 61d and 61e) which have been already measured.
With the above-described method of adjusting the LUT 102, it is possible to determine whether the process gray gradation patches 62 are each achromatic and have the same gradation (density), and to know the density level of each patch 62. Accordingly, sufficient data for performing the density or chromaticity control with high accuracy can be detected without being affected by not only contamination of the sensor due to scattering of paper dust, toners and ink, but also variations in spectroscopic characteristics of the sensor.
Further, the image forming apparatus having good density versus gradation characteristics can be provided by adjusting the LUT 102, i.e., by properly adjusting the amounts of the mixed toners of three colors for each of plural gradations so that the process gray gradation patch formed by mixing the toners of three colors, i.e., yellow, magenta and cyan, becomes achromatic, and then feeding the adjusted results back to the image processing control section 101 for adjustment of the image forming conditions.
In step S901, the image processing control section 101 modifies, based on the color matching table prepared in advance, an RGB signal representing an image color and transmitted from an external host, such as a personal computer, through computation using the predetermined compensation factors for conversion into a device RGB signal (referred to as a “DevRGB signal” hereinafter) in match with the color reproducible range of the image forming apparatus 100.
In step S902, the image processing control section 101 modifies, based on the color decomposing table prepared in advance, the DevRGB signal through computation using the predetermined compensation factors for conversion into a CMYK signal regarding the colors of toner dyes used in the image forming apparatus 100.
In step S903, the image processing control section 101 converts, based on the calibration table for compensating the density versus gradation characteristics specific to each image forming apparatus 100, the CMYK signal into a C′M′Y′K′ signal, which has been modified for compensation of the density versus gradation characteristics, through computation using the predetermined tables for conversion. That conversion is performed by a method of storing C signals for a plurality of gradations (e.g., five gradations a-e) and C′ signals corresponding to the C signals, as the calibration table, in the LUT 102 beforehand, and then converting the input C signal into the corresponding C′ signal by employing the stored C and C′ signals. To explain by way of example, the C signals for the five gradations a-e and the corresponding C′ signals are stored, as Ca and C′a, Cb and C′b, Cc and C′c, Cd and C′d, and Ce and C′e, in the LUT 102 beforehand. When converting the input C signal into the corresponding C′ signal, the values stored in the calibration table of the LUT 102 are employed. For example, when the C signal at a gradation f between the gradations a and b is input as Cf, the Cf signal is converted into a C′f signal through linear interpolation based on the following formula (1) by using Ca, C′a, Cb and C′b stored in the calibration table of the LUT 102:
C′f=Cf.(C′a−C′b)/(Ca−Cb)+(Cb.C′a−Ca.C′b)/(Cb−Ca) (1)
While the above description is made of the conversion from the C signal into the C′ signal, conversion from an M signal into an M′ signal and conversion from a Y signal into Y′ signal can also be executed in a similar manner through linear interpolation. As a matter of course, any suitable one of other interpolation methods can also be used instead of the linear interpolation.
In step S904, based on the PWM table, the C′M′Y′K′ signal is modified through computation using the predetermined compensation factors for conversion into exposure times Tc, Tm, Ty and Tk for the scanner sections 27C, 27M, 27Y and 27K corresponding to the C′M′Y′K′ signal.
Through the above-described steps, the image signal input from the external host is converted into the laser exposure time for the scanner section 27.
The adjustment of the LUT 102 executed in step S806 of
As a result of the adjusting operation described above, the amounts of the mixed toners of C, M and Y are properly adjusted so that the chromaticity difference between the monochrome gray gradation patch 61 and the process gray gradation patch 62 is held within the predetermined value.
In the above-described control method, the image processing control section 101 adjusts the LUT 102 (more precisely, the calibration table in the LUT 102) so that the desired density or chromaticity can be obtained. As another embodiment, a stable image can also be obtained with density or chromaticity control in which, after detecting the density or chromaticity of the toner patch pattern 60, the image forming control section 103 directly controls, for example, the amount of exposure of the laser beam emitted from the scanner section 27 or the developing bias applied from the developing unit 25 depending on the detected result. Alternatively, it is also possible to select, as required, one of the methods of controlling the image forming operation in accordance with the result detected by the color sensor 50 and controlling the density or chromaticity of the image having been fused.
In addition, this embodiment is applicable to the case where the image forming control section 103 detects the toner density patch pattern 44, which is formed on the intermediate transfer member 12, using the photosensor 40 for density control provided separately from the color sensor 50, and the amount of exposure of the laser beam emitted from the scanner section 27 or the developing bias applied from the developing unit 25 is controlled depending on the detected result. In that case, the result detected by the photosensor 40 for density control is modified for each of plural gradations, and the amount of exposure of the laser beam emitted from the scanner section 27 or the developing bias applied from the developing unit 25 is controlled in accordance with the modified detected result. As a result, the amounts of the mixed toners of C, M and Y are properly adjusted so that the chromaticity difference between the monochrome gray gradation patch 61 and the process gray gradation patch 62 is held within the predetermined value.
The switchback mechanism 17 includes feed means such as a feed path for the transfer material 22 and a feed roller (switchback roller) for reversing the transfer material 22 the obverse side down. The duplex unit 18 includes an accommodating section for receiving the transfer material 22 fed from the switchback mechanism 17 and holding it to be ready for the image formation on the reverse side, and feed means such as a feed path and a feed roller for the transfer material 22.
In the first embodiment, the color sensor 50 is disposed in the middle of the transfer-material feed path at a position between the switchback mechanism 17 and the transfer roller 13 (i.e., the secondary transfer section T2) to face the side of the transfer material 22 on which the toner patch pattern 60 is formed. Preferably, as shown in
A description is now made of the feed path of the transfer material 22 fed under control of the image forming apparatus 100 with reference to FIG. 10.
After the detection of the density or chromaticity of the toner patch pattern 60, the transfer material 22 is advanced to the sheet ejecting section 19 via the transfer roller 13, the fusing unit 14, and the duplex flapper 16 (S1008). As described above, this second embodiment is featured in that the color sensor 50 is disposed in the middle of the transfer-material feed path at a position between the switchback mechanism 17 and the transfer roller 13, the transfer material 22 including the toner image having been fused is fed to the position of the color sensor 50 via the switchback mechanism 17 and the duplex unit 18 for detecting the density or chromaticity of the toner patch pattern 60 by the color sensor 50, and after the detection, the transfer material 22 is advanced to the sheet ejecting section 19 via the transfer roller 13 and the fusing unit 14.
So long as an image forming apparatus has the switchback mechanism 17 and the duplex unit 18, the first embodiment is practically feasible just by providing the color sensor 50 in the predetermined position without changing the apparatus structure at all. Also, the color sensor 50 is disposed at a position that is sufficiently away from the fusing unit 14 and is free from the effect of the heat radiated from the fusing unit 14. Further, the time taken for the transfer material 22 to reach the position of the color sensor 50 after the fusing of the toner patch pattern 60 is set such that the transfer material 22 heated by the fusing unit 14 is sufficiently cooled down to a level of temperature at which the color sensor 50 causes neither deformations nor variations of characteristics and hence the detection reliability does not deteriorate.
Thus, with the arrangement of the color sensor 50 and the feed path of the transfer material 22 according to the first embodiment, since the distance between the color sensor 50 and the fusing unit 14 is sufficiently large and the temperature of the transfer material 22 is reduced down while it is fed to the position of the color sensor 50, the color sensor 50 can be prevented from being affected by the heat radiated from the fusing unit 14 and the heat still remaining in the transfer material 22.
Consequently, this first embodiment can realize the density or chromaticity control with high accuracy and high reliability.
(Second Embodiment)
A second embodiment of the present invention will be described below.
The second embodiment is similar to the first embodiment in that the toner patch pattern 60 having the patch array shown in
The operation of the image forming apparatus 100 according to the second embodiment will be described with reference to a flowchart of FIG. 11.
When the image forming control section 103 receives a control command instructing control of the density or chromaticity from the image processing control section 101 in step S1101, it starts feed of the transfer material 22 from the sheet feed section 11 in step S1102.
In step S1103, the image forming control section 103 executes the control process for transferring the toner image onto the obverse (first) side of the transfer material 22 with the action of the secondary transfer roller 13 as described above.
In step S1104, the image forming control section 103 executes the control process for feeding the transfer material 22 to the fusing unit 14 and then fusing and fixing the toner image to the transfer material 22.
In step S1105, the image forming control section 103 controls the duplex flapper 16 to take a position (indicated by 16u in
In step S1106, the image forming control section 103 executes the control process for feeding the transfer material 22, which has been reversed through the switchback mechanism 17, in the duplex unit 18.
In step S1107, the color sensor 50 detects the toner patch pattern 60 in a position that is set for the detection by the color sensor 50 which exists in the middle of the feed path of the transfer material 22 toward a secondary transfer section T2. Also, the image processing control section 101 adjusts the compensation factors in the LUT 102 based on the detection result of the density or chromaticity received from the color sensor 50 through the image forming control section 103.
In step S1108, the image forming control section 103 determines whether the color sensor 50 has detected the toner patch pattern 60 formed on the rear (second) side of the transfer material 22. If only the toner patch pattern 60 on the first side has been detected (i.e., if the determination result in step S1108 is “NO”), the process flow returns to step S1103 for transferring the toner patch pattern 60 onto the rear (second) side of the transfer material 22. Thereafter, the operations of steps S1104 to S1107 are repeated.
If it is determined in step S1108 that the toner patch pattern 60 on the second side has already been detected (i.e., if the determination result in step S1108 is “YES”), the process flow advances to step S1109 in which the image forming control section 103 controls the duplex flapper 16 to take a position (indicated by 16d in
The density or chromaticity control executed by the image forming control section 103 and the image processing control section 101 in step S1107 is the same as that described above in the first embodiment, and hence is not described here.
In the above-described control method, the image processing control section 101 adjusts the LUT 102 so that the desired density or chromaticity can be obtained. As another embodiment, a stable image can also be obtained with density or chromaticity control in which, after detecting the density or chromaticity of the toner patch pattern 60, the image forming control section 103 directly controls, for example, the amount of exposure of the laser beam emitted from the scanner section 27 or the developing bias applied from the developing unit 25 depending on the detected result. Alternatively, it is also possible to select, as required, one of the methods of controlling the image forming operation in accordance with the result detected by the color sensor 50 and controlling the density or chromaticity of the image having been fused.
In addition, this embodiment is applicable to the case where the image forming control section 103 detects the toner density patch pattern 44, which is formed on the intermediate transfer member 12, using the photosensor 40 for density control provided separately from the color sensor 50, and the amount of exposure of the laser beam emitted from the scanner section 27 or the developing bias applied from the developing unit 25 is controlled depending on the detected result. In that case, the result detected by the photosensor 40 for density control is modified for each of plural gradations, and the amount of exposure of the laser beam emitted from the scanner section 27 or the developing bias applied from the developing unit 25 is controlled in accordance with the modified detected result. As a result, the amounts of the mixed toners of C, M and Y are properly adjusted so that the process gray gradation patch becomes achromatic.
The second embodiment has features, in addition to those of the first embodiment, in that the density or chromaticity control can be performed on both sides of the transfer material 22 in the duplex image forming process and the transfer material 22 is fed through the path enabling the density or chromaticity control to be performed on both sides of the transfer material.
Additionally, in order that the density or chromaticity control can be properly performed by forming the toner patch patterns 60 on both sides of the transfer material 22 even when identical images formed on the obverse side and the reverse side have colors slightly different from each other, the image processing control section 101 may be designed such that two sets of compensation factors in the LUT 102 are separately prepared for the obverse (first) side and the reverse (second) side of the transfer material 22, thus allowing the sets of compensation factors in the LUT 102 to be adjusted independently of each other for the obverse side and the reverse side of the transfer material 22.
Moreover, by forming the toner patch patterns 60 having different gradations on both sides of the transfer material 22, the image forming control section 103 can improve the compensation accuracy with an increase in the number of the toner patch patterns for use in adjusting the LUT 102 and hence can improve the compensation accuracy. In that case, since the number of gradations, for each of which the compensation factors in the LUT 102 are adjusted, is doubled in comparison with the case of forming the toner patch pattern 60 on the obverse (first) side alone, the gradation adjustment can be more finely performed.
Thus, with the arrangement of the color sensor 50, the formation of the toner patch patterns 60 on both sides of the transfer material 22, and the feeding method (feed path of the transfer material 22) according to the second embodiment, since the distance between the color sensor 50 and the fusing unit 14 is sufficiently large and the temperature of the transfer material 22 is reduced while it is fed to the position of the color sensor 50, the color sensor 50 can be prevented from being affected by the heat radiated from the fusing unit 14 and the heat still remaining in the transfer material 22. In addition, the density or chromaticity control can be performed on both sides of the transfer material 22 in the process of duplex image forming.
(Third Embodiment)
A third embodiment of the present invention will be described below.
As shown in
Further, in the third embodiment, the image forming control section 103 can control the first and second switchback flappers 20a, 20b such that the transfer material 22 can be advanced from the switchback mechanism 17 to the sheet ejecting section 19 without passing the duplex unit 18. When the transfer material 22 is advanced from the switchback mechanism 17 to the sheet ejecting section 19, the first and second switchback flappers 20a, 20b are moved to rightward deviated positions as indicated by solid lines 20ar, 20br in FIG. 7.
The operation of the image forming apparatus 100 according to the third embodiment will be described with reference to a flowchart of FIG. 13.
When the image forming control section 103 receives a signal instructing the formation of the toner patch pattern 60 from the image processing control section 101 in step S1301, it starts feed of the transfer material 22 from the sheet feed section 11 in step S1302.
In step S1303, the image forming control section 103 executes the control process for transferring the toner image onto the obverse (first) side of the transfer material 22 with the action of the secondary transfer roller 13 as described above.
In step S1304, the image forming control section 103 executes the control process for feeding the transfer material 22 to the fusing unit 14 and then fusing and fixing the toner image to the transfer material 22.
In step S1305, the image forming control section 103 controls the duplex flapper 16 to take a position (indicated by 16u) in which its fore end is raised. Thereby, the transfer material 22 having the toner image formed thereon is fed to the switchback mechanism 17. The density or chromaticity of the toner patch pattern 60 is detected at the position of the color sensor 50. Then, the image processing control section 101 adjusts the LUT 102 based on the detection result of the density or chromaticity received from the color sensor 50 through the image forming control section 103.
In step S1306, the feed direction of the transfer material 22 is changed over from a direction D1 to a direction D3 shown in
In step S1307, the image forming control section 103 executes the control process for advancing the transfer material 22 to the sheet ejecting section 19.
The density or chromaticity control executed by the image forming control section 103 and the image processing control section 101 in step S1305 is the same as that described above in the first embodiment, and hence is not described here.
In the above-described control method, the image processing control section 101 adjusts the LUT 102 so that the desired density or chromaticity can be obtained. As another embodiment, a stable image can also be obtained with density or chromaticity control in which, after detecting the density or chromaticity of the toner patch pattern 60, the image forming control section 103 directly controls, for example, the amount of exposure of the laser beam emitted from the scanner section 27 or the developing bias applied from the developing unit 25 depending on the detected result. Alternatively, it is also possible to select, as required, one of the methods of controlling the image forming operation in accordance with the result detected by the color sensor 50 and controlling the density or chromaticity of the image having been fused.
In addition, this embodiment is applicable to the case where the image forming control section 103 detects the toner density patch pattern 44, which is formed on the intermediate transfer member 12, using the photosensor 40 for density control provided separately from the color sensor 50, and the amount of exposure of the laser beam emitted from the scanner section 27 or the developing bias applied from the developing unit 25 is controlled depending on the detected result. In that case, the result detected by the photosensor 40 for density control is modified for each of plural gradations, and the amount of exposure of the laser beam emitted from the scanner section 27 or the developing bias applied from the developing unit 25 is controlled in accordance with the modified detected result. As a result, the amounts of the mixed toners of C, M and Y are properly adjusted so that the process gray gradation patch becomes achromatic.
Moreover, as shown in
With reference to
After the detection of the density or chromaticity of the toner patch pattern 60, the transfer material 22 is advanced to the sheet ejecting section 19 through the two switchback flappers 20a, 20b (S1407, S1408).
As described above, this third embodiment is featured in that the color sensor 50 is disposed in the switchback mechanism 17, and that the transfer material 22 is fed to the switchback mechanism 17 and, after the detection of the density or chromaticity, it is advanced to the sheet ejecting section 19 through the two switchback flappers 20a, 20b without passing the duplex unit 18 and the image forming section A. With those features, the total feed path of the transfer material 22 from the supply to the ejection becomes shorter than that required in the image forming apparatus 100 according to the first embodiment.
The image forming apparatus 100 according to the third embodiment includes, as shown in
Also, the color sensor 50 is disposed at a position that is sufficiently away from the fusing unit 14 and is free from the effect of the heat radiated from the fusing unit 14. Further, the time taken for the transfer material 22 to reach the position of the color sensor 50 after the fusing of the toner patch pattern 60 is set such that the transfer material 22 heated by the fusing unit 14 is sufficiently cooled down to a level of temperature at which the color sensor 50 causes neither deformations nor variations of characteristics and hence the detection reliability does not deteriorate. Additionally, since the feed distance of the transfer material 22 is shorter in the third embodiment than in the first embodiment, the time required for a series of control operations in the third embodiment becomes shorter than that in the first embodiment.
Thus, with the arrangement of the color sensor 50 and the feed path of the transfer material 22 according to the third embodiment, since the distance between the color sensor 50 and the fusing unit 14 is sufficiently large and the temperature of the transfer material 22 is reduced while it is fed to the position of the color sensor 50, the color sensor 50 can be prevented from being affected by the heat radiated from the fusing unit 14 and the heat still remaining in the transfer material 22. Moreover, since the total feed path of the transfer material 22 is shortened with the provision of the switchback flappers 20a, 20b, the detection of the density or chromaticity is completed in a shorter time.
Consequently, this third embodiment can realize the density or chromaticity control in a shorter time with high accuracy and high reliability.
(Fourth Embodiment)
A fourth embodiment of the present invention will be described below.
The fourth embodiment is similar to the third embodiment in that the image forming apparatus has the construction shown in
The operation of the image forming apparatus 100 according to the fourth embodiment will be described with reference to a flowchart of FIG. 15.
When the image forming control section 103 receives a signal instructing the formation of the toner patch pattern 60 from the image processing control section 101 in step S1501, it starts feed of the transfer material 22 from the sheet feed section 11 in step S1502.
In step S1503, the image forming control section 103 executes the control process for transferring the toner image onto the obverse (first) side of the transfer material 22 with the action of the secondary transfer roller 13 as described above.
In step S1504, the image forming control section 103 executes the control process for feeding the transfer material 22 to the fusing unit 14 and then fusing and fixing the toner image to the transfer material 22.
In step S1505, the image forming control section 103 controls the duplex flapper 16 to take a position (indicated by 16u) in which its fore end is raised. Thereby, the transfer material 22 having the toner image formed thereon is fed to the switchback mechanism 17. The density or chromaticity of the toner patch pattern 60 is detected at the position of the color sensor 50. Then, the image processing control section 101 adjusts the LUT 102 based on the detection result of the density or chromaticity received from the color sensor 50 through the image forming control section 103.
In step S1506, the image forming control section 103 controls the switchback mechanism 17 to change over the feed direction of the transfer material 22 so that the transfer material 22 is reversed.
In step S1507, it is determined whether the toner patch pattern 60 formed on the reverse (second) side of the transfer material 22 has been detected. If the toner patch pattern 60 on the second side is not yet detected (i.e., if the determination result in step S1507 is “NO”), the process flow returns to step S1503 and then executes the control operations of steps S1503 to S1507.
More specifically, under control of the image forming control section 103, the toner patch pattern 60 is transferred onto the reverse (second) side of the transfer material 22 when the transfer material 22 passes the transfer roller 13 (S1503). Then, the toner patch pattern 60 is fused and fixed to the transfer material 22 while the transfer material 22 is passing the fusing unit 14 (step S1504). Then, the toner patch pattern 60 formed on the reverse (second) side of the transfer material 22 is detected, and the LUT 102 is adjusted based on the detection result (step S1505). Finally, the feed direction of the transfer material 22 is changed over such that the transfer material is reversed (step S1506).
If it is determined in step S1507 that the toner patch pattern 60 on the second side of the transfer material 22 has already been detected, the process flow advances to step S1508.
In step S1508, the image forming control section 103 executes the control process for advancing the transfer material 22 to the sheet ejecting section 19.
In the above-described control method, the image processing control section 101 adjusts the LUT 102 so that the desired density or chromaticity can be obtained. As another embodiment, a stable image can also be obtained with density or chromaticity control in which, after detecting the density or chromaticity of the toner patch pattern 60, the image forming control section 103 directly controls, for example, the amount of exposure of the laser beam emitted from the scanner section 27 or the developing bias applied from the developing unit 25 depending on the detected result. Alternatively, it is also possible to select, as required, one of the methods of controlling the image forming operation in accordance with the result detected by the color sensor 50 and controlling the density or chromaticity of the image having been fused.
In addition, this embodiment is applicable to the case where the image forming control section 103 detects the toner density patch pattern 44, which is formed on the intermediate transfer member 12, using the photosensor 40 for density control provided separately from the color sensor 50, and the amount of exposure of the laser beam emitted from the scanner section 27 or the developing bias applied from the developing unit 25 is controlled depending on the detected result. In that case, the result detected by the photosensor 40 for density control is modified for each of plural gradations, and the amount of exposure of the laser beam emitted from the scanner section 27 or the developing bias applied from the developing unit 25 is controlled in accordance with the modified detected result. As a result, the amounts of the mixed toners of C, M and Y are properly adjusted so that the process gray gradation patch becomes achromatic.
Additionally, in order that the density or chromaticity control can be properly performed by forming the toner patch patterns 60 on both sides of the transfer material 22 even when identical images formed on the obverse side and the reverse side have colors slightly different from each other, the image processing control section 101 may be designed such that two LUTs 102 are separately prepared for the obverse (first) side and the reverse (second) side of the transfer material 22, thus allowing the two LUTs 102 to be adjusted independently of each other for the obverse side and the reverse side of the transfer material 22.
Moreover, by forming the toner patch patterns 60 having different gradations on both sides of the transfer material 22, the image forming control section 103 can improve the compensation accuracy with an increase in the number of the toner patch patterns for use in adjusting the LUT 102. In that case, since the number of gradations, for each of which the LUT 102 is adjusted, is doubled in comparison with the case of forming the toner patch pattern 60 on the obverse (first) side alone, the gradation adjustment can be more finely performed.
With reference to
After the detection of the density or chromaticity of the toner patch pattern 60 on the obverse side, the transfer material 22 is fed again through the duplex unit 18. Then, the toner patch pattern 60 formed on the intermediate transfer member 12 is transferred onto the reverse (second) side of the transfer material 22. While passing through the fusing unit 14, the toner patch pattern 60 is fused and fixed to the transfer material 22. Subsequently, the transfer material 22 having the toner patch pattern 60 formed thereon is advanced to the switchback mechanism 17 with the aid of the duplex flapper 16, and the density or chromaticity of the toner patch pattern 60 on the reverse (second) side of the transfer material 22 is detected by the color sensor 50 disposed in the switchback mechanism 17.
After the detection of the density or chromaticity of the toner patch pattern 60 on the reverse side, the transfer material 22 is advanced to the sheet ejecting section 19 through the two switchback flappers 20a, 20b.
As described above, this fourth embodiment has features, in addition to the features of the third embodiment, in that the density or chromaticity control can be performed on both sides of the transfer material 22 in the duplex image forming process, and that after detecting the density or chromaticity of the toner patch pattern 60 formed on each of both sides of the transfer material 22, the transfer material 22 is advanced to the sheet ejecting section 19 through the two switchback flappers 20a, 20b without passing the image forming section A. Thus, the total feed path of the transfer material 22 becomes shorter than that required in the second embodiment.
Thus, with the arrangement of the color sensor 50, the formation of the toner patch patterns on both sides of the transfer material 22, and the feed path of the transfer material 22 according to the fourth embodiment, since the distance between the color sensor 50 and the fusing unit 14 is sufficiently large and the temperature of the transfer material 22 is reduced while it is fed to the position of the color sensor 50, the color sensor 50 can be prevented from being affected by the heat radiated from the fusing unit 14 and the heat still remaining in the transfer material 22. Further, the density or chromaticity control can be performed on both sides of the transfer material in the duplex image forming process. In addition, since the total feed path of the transfer material 22 is shortened with the provision of the switchback flappers 20a, 20b, the detection of the density or chromaticity is completed in a shorter time.
Consequently, this fourth embodiment can realize the density or chromaticity control for images on both sides of the transfer material in a shorter time with high accuracy and high reliability.
While the above first to fourth embodiments have been described as applying the present invention to a tandem color image forming apparatus in which the image forming section A includes the plurality of image forming units and the intermediate transfer member 12, the present invention is not limited to that type of apparatus. As well known to those skilled in the art, there are other types of image forming apparatuses. In one type, for example, toner images are successively transferred from a plurality of image carriers, e.g., photoconductors, onto a transfer material supported on a transfer-material feed means, and then fused. In another type, toner images of multiple colors are successively formed on a single image carrier, e.g., a single photoconductor. Thereafter, the toner images are successively transferred onto a transfer material supported on a transfer-material feed means in a superimposed relation, or the toner images are successively transferred onto an intermediate transfer member in a superimposed relation and then transferred onto a transfer material together. The present invention can be likewise applied to those image forming apparatuses and can provide similar advantages as those described above.
According to the embodiments, as described above, the density or chromaticity of an image having been formed on a transfer material 22 and fused can be stably detected and controlled with high accuracy and high reliability without being affected by the heat attributable to that the surroundings of the fusing unit 14 are heated to very high temperature due to the heat generated from the fusing unit 14 itself and the transfer material 22 immediately after the fusing is heated to high temperature by the fusing unit 14.
Further, according to the embodiments, image forming apparatuses having the following advantages in addition to the above-mentioned advantages can be provided. In one apparatus, the density or chromaticity of an image having been formed on a transfer material and fused can be detected and controlled in a shorter time. In another apparatus, the density or chromaticity of an image having been formed on each of both sides of a transfer material and fused can be detected and controlled. In still another apparatus, the density or chromaticity of an image having been formed on each of both sides of a transfer material and fused can be detected and controlled in a shorter time.
(Other Embodiments)
With the first to fourth embodiments described above, in the electrophotographic image forming apparatus, the chromaticity and/or gradation of an image is properly controlled by forming and fusing the toner patch pattern 60 on the transfer material 22, detecting the toner patch pattern 60 by the color sensor 50, and adjusting the LUT 102.
However, the present invention is also applicable to an ink jet image forming apparatus in addition to the electrophotographic image forming apparatus. In other words, the chromaticity and/or gradation of an image can also be properly controlled by ejecting inks of multiple colors toward a recording medium in response to image signals from an image forming section, such as an ink head, to thereby form an ink patch pattern on the recording medium, detecting the ink patch pattern by the color sensor 50, and adjusting the LUT 102.
In that case, similar advantages to those in the first to fourth embodiments can be obtained by arranging the image forming section, such as an ink head, in the same position as the image forming section A shown in
While the present invention has been described with reference to what are presently considered to be the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. On the contrary, the invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. 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.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2002-015933 | Jan 2002 | JP | national |
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| Number | Date | Country | |
|---|---|---|---|
| 20030138261 A1 | Jul 2003 | US |
