Patent Grant
7398027
1. Field of the Invention
The present invention relates to an image forming apparatus that transfers unfixed images to recording materials by a transfer means, and fixes the unfixed images on the recording materials by a fixing means.
2. Description of the Related Art
Conventionally, as shown in
The fixing roller pair 105 heat-fixes the unfixed images to the recording materials. However, the heat temporarily removed from the fixing rollers through the fixing process varies depending on amount of deposit of developer that forms unfixed images transferred to the recording materials, the number of passing recording materials per unit time that passes through the fixing roller pair, difference in heat capacity of the recording materials. A temporary temperature change that takes place in the fixing roller pair 105 appears as a change of size of the outer diameter of the rollers. This might lead to a difference between the conveyance speed of the recording materials by the fixing roller pair 105 and the conveyance speed of the recording material by the transfer roller pair 103.
Such a difference between the conveyance speeds of the recording materials of the fixing roller pair 105 and the transfer roller pair 103, if any, might result in a deterioration of the image. In other words, when the conveyance speed of the recording materials by the fixing roller pair 105 is faster than that of the recording materials by the transfer roller pair 103, the recording materials are stretched between the fixing roller pair 105 and the transfer roller pair 103, causing image disturbance or the like, thereby leading to image deterioration when images are transferred to the recording materials P by the transfer roller pair. On the other hand, when the conveyance speed of the recording materials by the fixing roller pair 105 is slower than that of the recording materials by the transfer roller pair 103, the recording materials form an oversize loop between the fixing roller pair 105 and the transfer roller pair 103. Then, the recording materials P that form the oversize loop are pressed hard and scraped against a conveyance guide 120, and the scraping against the conveyance guide 120 might cause image disturbance, thereby resulting in deteriorated images when they are transferred. Thus, the following proposal has been made previously for solving the problem of image deterioration as described above, by forming a predetermined loop on recording materials P between the transfer roller pair 103 and the fixing roller pair 105 and thus preventing the recording materials P from being stretched or bending too much.
As shown in
In order to maintain recording materials in a predetermined loop, however, the fixing roller pair is switched to the first speed or the second speed so that a predetermined loop can be maintained. Thus, there is a fear that noise would result from the switching of the conveyance speed of the fixing roller pair. In addition, there is also another fear that poor images might occur, such as image blurring at the transfer portion or fixing nonuniformity at the fixing device, due to periodic minor vibration caused by the switching operation of the conveyance speed.
It is an object of the present invention to reduce occurrence of noise or poor images, etc., due to switching of conveyance speed of a fixing roller pair, while preventing image deterioration attributable to recording materials that are stretched or bend too much between a transfer roller pair and the fixing roller pair. The present invention includes a transfer means which transfers unfixed images borne by an image bearing member to recording materials, a fixing means which fixes the transferred unfixed images on the recording materials, a loop detecting means which detects a loop of the recording materials to be formed between the transfer means and the fixing means, a recording material detection means which determines that the recording materials have reached to the fixing means, and a control means which controls conveyance speed of the recording materials by the fixing means, wherein based on the detection result of the recording material detection means and the loop detecting means and, length of the recording material, the control means sets the conveyance speed of the fixing means so that when a rear end of the recording material passes through the transfer means after the loop detecting means detected the loop of the recording material, a loop length of the recording material will be set to a lower limit length, and the control means controls the conveyance speed of the fixing means at the set conveyance speed.
In the following, with reference to the drawings, preferred embodiments will be illustratively described in details. Provided that dimensions, materials, shapes, relative arrangement thereof of components described in the following embodiments should be changed as appropriate according to configuration or various conditions of an apparatus to which the present invention is applied, and it is not intended that the scope of the invention is limited to them unless otherwise specified.
Here, an image forming apparatus according to a first embodiment of the invention will be described with reference to the drawings.
First, a schematic configuration of the entire image forming apparatus will be described with reference to
The image forming apparatus 30 shown in
Around the respective photosensitive drums a, b, c, and d driven by a motor (not shown), a primary charger, a development device and the like. (respectively not shown) are arranged, and unitized as process cartridges 1a, 1b, 1c, and 1d that can be detachably loaded into the main body of the image forming apparatus 30.
In addition, an exposure device 6 composed of a polygon mirror and the like is arranged beneath the photosensitive drums a to d.
First, laser light by an image signal in yellow component color is projected to the photosensitive drum a in a first image forming device via a polygon mirror of an exposure device 6, etc., an electrostatic latent image is formed on the photosensitive drum a, to which yellow toner is supplied from the development device for development, and the electrostatic latent image is visualized as an yellow toner image.
When the toner image reaches a first transfer member against which the photosensitive drum a and the intermediate transfer belt 2 abut, as the photosensitive drum a rotates, primary transfer bias applied to a transfer charging member 2a allows the yellow toner image on the photosensitive drum a to be transferred to the intermediate transfer belt 2 (primary transfer). When the member bearing the yellow toner image of the intermediate transfer belt 2 moves to the next image forming portion, a magenta toner image has been formed on the photosensitive drum b and in the primary transfer member against which the photosensitive drum b in the process similar to that for the above image forming portion, and the intermediate transfer belt 2 abut, the magenta image is superimposed on the yellow toner image on the intermediate transfer belt 2, and then transferred. At the same time, in the primary transfer member, a cyan toner image and a black toner image are sequentially superimposed on the yellow toner image and magenta toner image, and then transferred as the intermediate transfer belt 2 moves.
On the other hand, recording materials P are housed in a cassette 4. Sent out sheet by sheet by a pickup roller 8, the recording materials P reach a secondary transfer member after being timed by a registration roller 9, the four-color toner images on the intermediate transfer belt 2 are collectively transferred onto the recording material P by the secondary transfer bias applied to a secondary transfer roller pair 3 as a transfer means (secondary transfer).
Then, the recording material P on which the four-color toner images are transferred is guided by a conveyance guide 20, conveyed to a fixing roller pair 5 as a fixing means located above the transfer roller pair 3, where the four-color toner images are fixed by heat and pressure. This enables toner of respective colors to melt, mix, and fix as a full-color print image on the recording materials P. Then, recording material P is guided by the conveyance guides 21, 22, the recording materials P on which the image is fixed are discharged to a discharge tray 7 by a discharge roller pair 11 as a discharge means provided downstream of the fixing roller pair 5.
In the case of single-side mode wherein an image is formed on one side of recording materials P, the recording material P on one side of which the image is formed as described above is discharged to the discharge tray 7 by the discharge roller pair 11. On the other hand, in the case of double-side mode wherein an image is formed on both sides of recording materials P, the recording material P on one side of which the image is formed as described above passes through a double-sided path (not shown), and conveyed to a registration roller pair 9 while both sides being inverted. Then, recording on the backside is completed with the image forming process similar to the front face recording, and then the recording material P on both sides of which the image is formed on the both sides is discharged to the discharge try by a discharge roller pair 11.
Here, with reference to
As shown in
In the present embodiment, the recording material detection means includes a clutch 13 that transmits (ON) or cuts off (OFF) the driving force to the registration roller pair 9 and a timer 14 that measures time after the clutch 13 has turned ON, and calculates that the recording material P has reached the nip of the fixing roller pair 5. In addition, CPU 17 controls the drive of fixing motor M, which is a fixing drive portion for driving the fixing roller pair 5, and calculates an arbitrary conveyance speed based on the detected result of the recording material detection means and the loop detecting sensor 12, and the information on the recording materials P that has been stored in the memory 50 in advance. Then, CPU 17 can set the conveyance speed of the recording material by the fixing roller pair 5 to the arbitrary conveyance speed. In other words, CPU 17 controls driving of the fixing motor M so that the fixing roller pair 5 can convey the recording materials at the set conveyance speed.
In addition, the fixing roller pair 5 of which the conveyance speed is set by the CPU 17 conveys the recording material P that runs into the nip of the fixing roller pair 5 at a constant recording material conveyance speed Vfa after the loop detecting sensor 12 detects a loop of the recording materials P. A constant recording material conveyance speed Vfa of the set fixing roller pair, to be detailed later, is constant conveyance speed that allows the loop length of the recording material P to be a length of lower limit La (See
Here, a control system of the image forming apparatus will be described. As shown in
In addition, the information relating to the recording materials P is at least one of mode information that shows image formation on a single side or both sides of the recording materials P, information on thickness and a type of the recording materials, and the environmental information. As shown in
In the following, in the image forming apparatus of the above configuration, the behavior of the fixing roller pair 5 will be described including the loop control of the recording materials to take place between the transfer roller pair 3 and the fixing roller pair 5.
The recording materials P is sent out sheet by sheet from the cassette 4 by the pickup roller 8 and timed by stopped registration rollers 9. Then, when the clutch 13 is turned ON (Step S21), driving force is transmitted to the registration rollers 9 that then convey the recording material P toward the secondary transfer roller pair 3. In addition, at the same time when the clutch 13 is turned ON, the timer 14 starts counting (Step S22).
The recording material P on which the four-color toner image was collectively transferred (secondary transfer) by the secondary transfer roller pair 3 is guided by the conveyance guide 20, and runs into the nip part of the fixing roller pair 5 while forming a loop of L0 as shown in
Then, when length of the loop of the recording materials P between the secondary transfer roller pair 3 and the fixing roller pair 5 reaches L1 as shown in
Then, the actual speed Vf=Vt−(L1−L0) of the conveyance speed of the recording material of the fixing roller pair 5 is calculated from the loop formation time T.
Then, the recording material P that runs into the nip of the fixing roller pair 5 and for which the loop L1 is detected by the loop detecting sensor 12 is, as described above, conveyed at the constant conveyance speed Vfa by the fixing roller pair 5 the conveyance speed of which is set by the CPU 17. The conveyance speed of the recording material Vfa of the fixing roller pair 5 is set to fall within the range expressed by the following expressions (1), (2), based on the detected count time T0 and the setting information stored in advance in the memory 50 (See
The conveyance speed Vfa till the rear end of a sheet comes out of the secondary transfer roller pair 3 should satisfy the following relationship for preventing a loop from being formed excessively large between the secondary transfer roller pair 3 and the fixing roller pair 5 or from preventing a loop from being stretched from both sides. T2 is the time from when the loop detecting sensor that detects the loop till the rear end of the sheet comes out of the secondary transfer roller pair 3.
Vt+(L1−Lb)/T2≦Vfa≦Vt+(L1−La)/T2
Where since the sheet length is S, T2=(S−Vt×T−L0)/Vt, the following expression can be obtained by assigning this to the above expression.
Vt+(L1−Lb)×Vt/(S−Vt×T−L0)≦Vfa (1)
Vfa≦Vt+(L1−La)×Vt/(S−Vt×T−L0) (2)
The conveyance speed of the recording Vfa of the fixing roller pair 5 to be set within the range shown by (1) and (2) of the above expressions is conveyance speed that allows the loop length of the recording material P to be length of the lower limit La till the rear end of the recording sheet P comes out of the transfer roller pair 3. Then, the conveyance speed of the recording material Vfa is a constant conveyance speed faster than the conveyance speed of the recording material Vt by the transfer roller pair 3.
In the above expressions, L0 represents the loop length of the recording materials P between the transfer roller pair 3 and the fixing roller pair 5 when the recording materials P run into the fixing roller pair 5. L1 represents the loop length of the recording material P between the transfer roller pair 3 and the fixing roller pair 5 when the loop is detected by the loop detecting sensor 12. La represents the loop length at the lower limit of the recording materials P between the transfer roller pair 3 and the fixing roller pair 5. The loop length La is a lower limit value which causes the recording material P to be stretched between the transfer roller pair 3 and the fixing roller pair 5 if the loop length of the recording materials between the transfer roller pair 3 and the fixing roller pair 5 becomes smaller than La, in the present embodiment. However, the loop lower limit length La may not necessarily be limited to the border between the condition in which the loop of the recording materials is formed and the condition in which the loop is stretched (lower limit of the loop length), but may be set to the condition in which there remains some bending to the extent that the hopping of the rear end of the recording materials is not easily generated when the recording material P passes through the transfer roller pair 3. Lb represents the upper limit loop length of the recording material P between the transfer roller pair 3 and the fixing roller pair 5. The upper limit loop length Lb is the upper limit of the loop length that causes too much bending of the recording material P between the transfer roller pair 3 and the fixing roller pair 5, if the loop length between the transfer roller pair 3 and the fixing roller pair 5 exceeds Lb. The relationship among the loop length of the recording materials shall be La<L0<L1<Lb. In addition, Vt represents conveyance speed of the recording material of the transfer roller pair 3, and S is the length of the recording material in the conveyance direction.
As for L0, the loop length of the recording materials P between the transfer roller pair 3 and the fixing roller pair 5 when the recording materials runs into the fixing roller pair 5, if thickness of the recording materials is different, as shown in
As for the loop length L1 of the recording material P between the transfer roller pair 3 and the fixing roller pair 5 when the loop detecting sensor 12 detects a loop, angle of inclination slope in the vicinity of the nip of the respective roller pair differs depending on rigidity (thickness) of the recording materials P. In other words, the loop length L1 of the recording material P is greater in thin paper than that in thick paper. Thus, the loop length L1 of the recording material P shall be d3<d2<d1 if one example of the magnitude correlation among respective setting information is taken as shown in
If the recording sheet is thick, the lower limit loop length La of the recording sheet P of the transfer roller pair 3 and the fixing roller pair 5 may be loop length almost equal to the loop length in a stretched condition. However, if the recording material is plain paper that is thinner than thick paper and if it is in a high humidity environment, the recording material P may possibly ripple in the width direction that crosses the conveyance direction, as shown in
If the recording paper P is thin, the upper limit loop length Lb of the recording material P between the transfer roller pair 3 and the fixing roller pair 5 may be in the marginal condition of bending immediately before the recording material P touches the conveyance guide 20. However, if a loop is formed excessively large as with the case of the thin paper when the recording material is thicker than thin paper, the recording material P nipped by the transfer roller pair 3 slips, thus the images in the conveyance direction of the recording material may stretch or contract. Thus, loop length that does not affect image expansion/contraction shall be set for the upper limit loop length Lb of the recording material P. In other words, the upper limit loop length Lb of the recording material shall be f3<f2<f1 if one example of magnitude relation is taken as shown in
Although, as described above, these setting values L0, L1, La, Lb are exemplified that they are based on rigidity (paper thickness) of the recording materials, the respective setting values L0, L1, La, Lb may differ depending on humidity as environmental information, in addition to paper thickness. For instance, even if thin paper of the recording material has a same thickness, loop of the recording material will be larger if humidity as environment information is higher than in the case where the humidity is low. Thus, if the magnitude correlation among respective setting information in terms of humidity as environmental information is exemplified, they are c1>c4, d1>d4, e1>e4, f1>f4.
In addition, as for length of the recording material S2 in the conveyance direction, a setting value associated with the paper type information of user set information 15 is started. Also, in the present embodiment, the environmental sensor 16, the paper type information and the mode information shall be detected by the user setting information 15.
In the image forming apparatus of the present embodiment, when the rear end of the recording material P passes through the transfer roller pair 3 with the upper limit loop length being Lb, the rear end of the recording material P hops and causes poor images. Thus, as described above, the conveyance speed of the recording material Vfa by the paper of fixing rollers 5 is set so that the rear end of the recording material P can pass through the transfer roller pair 3 with the lower limit loop length being La as shown in
Then, if conveyance of the recording material by the fixing roller pair 5 continues at the conveyance speed of Vfa, after the rear end of the recording material P comes out of the secondary transfer roller pair 5, the recording materials P might scrape against the conveyance guides 21, 22, thereby causing poor images after fixing, because the conveyance speed Vfa is faster than the conveyance speed of the recording materials Vt by the transfer roller pair 3.
Thus, the timing for the rear end of the recording material P to come out of the secondary transfer roller pair 3 is set with a value of the count time of the timer 14, and the conveyance speed of the recording material Vfb of the fixing roller pair 5 is set to be equal to the conveyance speed of the recording material Vt of the transfer roller pair 3, when the predetermined time is reached (Step S27).
Then, the recording material P is discharged to the discharge tray by the discharge roller pair 11 provided downstream of the fixing roller pair 5.
In the present embodiment, it is exemplified that the configuration wherein as the recording material detection means for detecting or calculating that the end of the recording material has reached the nip of the fixing roller pair, the timing when the end of the recording materials P reaches the nip of the fixing roller pair is calculated from ON timing of the clutch 13 of the registration roller 9. However, the recording material detection means shall not be limited to this. For instance, the configuration may be acceptable wherein as the recording material detection means for detecting that the top end of the recording material has reached the nip of the fixing roller pair 5, as shown in
As described above, according to the present embodiment, any noise or poor images, etc. due to switching of the conveyance speed of the fixing roller pair 5 can be reduced, while preventing image deterioration due to the recording material P being stretched or bending too much between the transfer roller pair 3 and the fixing roller pair 5.
In addition, since the conveyance speed of the recording material Vfa of the fixing roller pair 5 can be calculated according to information on the recording material P, any poor images due to the loop condition of the recording material from when the recording material P is nipped by the fixing roller pair 5 till the time when it passes through the nip of the transfer roller pair 3. In addition, the conveyance speed of the recording materials Vfa of the fixing roller pair 5 can be calculated in a simple and inexpensive manner because the information on the recording material P uses the constants that have been set in advance in the memory 50, in calculating the conveyance speed of the recording material of the fixing roller pair 5.
In addition, even when the mode information such as single side/double side, paper thickness, paper type or environment is changed, a loop of appropriate recording material can be formed, thus reducing poor images due to the loop condition of the recording materials.
Since it is possible to reduce hopping of the recording materials P when the rear end of the recording materials passes through the nip of the transfer roller 3, poor images attributed to this can be cleared.
In addition, in the conveyance path following fixing after the rear end of the recording material passes through the nip of the transfer roller pair 3, the loop condition the recording material can be corrected appropriately, thus clearing poor images in the conveyance path after fixing. In addition, curled condition of the recording material can also be stabilized, and thus jamming or poor loading can be prevented.
Here, an image forming apparatus according to a second embodiment of the present invention will be described. The image forming apparatus according to the present embodiment is such a configuration that a loop detecting sensor 12 as the loop detecting means also has the operation sensing function for detecting whether or not the operation of conveying recording materials by the fixing roller pair works normally. The loop detecting sensor 12 is capable of detecting operations if the loop detecting sensor detects that the operation does not work normally, for instance, when printing is carried out in out-of-spec conditions, such as operational error by a user, printing on out-of-spec recording materials, or deterioration of parts due to duration, or the like.
In the following, the image forming apparatus according to the second embodiment will be described in details, with reference to
First, for example, ON timing of the clutch 13 starts the operation detecting function. And, as shown in
In this case, it is shown that the conveyance speed of recording material by the fixing roller pair 5 is faster than normal condition. Thus, the warning display here shows whether user setting is done as specified, or a message prompting for parts replacement.
If the loop detecting sensor turns ON normally within a given amount of time at the Step S91, as illustrated in the first embodiment, the conveyance speed of the recording material of the fixing roller pair 5 is set to be constant conveyance speed Vfa (Step S94). This allows the recording material P to be conveyed by the fixing roller pair 5 at the constant conveyance speed Vfa, while it is being conveyed by the transfer roller pair 3 at the conveyance speed Vt,
Then, the loop detecting sensor 12 detects whether or not the loop of the recording material P is cleared within a given amount of time (Step S95). If the fixing roller pair 5 conveys the recording material P at the constant conveyance speed Vfa, under normal conditions, the loop is cleared in the arrow direction 31 as shown in
According to the present embodiment, in addition to the effects of the above embodiment, in the case of deterioration due to the elapse of time or out-of-spec setting of the transfer roller pair or the fixing roller pair, the operation can be stopped by detecting loop condition of the recording medium if it does not work normally, and thus can issue a warning to the user.
In the above embodiments, as information on recording materials, mode information, information on thickness of recording materials, paper type information and environmental information are used, it is exemplified that the loop control that uses loop length L0, L1, La, Lb of the recording materials based on the various information and length of conveyance direction S of the recording material, however the present invention is not limited to this. As the information on recording materials, information on other recording materials such as mode information such as mode for forming monochrome images, mode for forming color images or the like, may be used. Alternatively, information on these recording materials may be used individually or in combination as appropriate, wherein similar effect to the above embodiments could be expected if loop length L0, L1, La, Lb of recording materials based on the information and length of conveyance direction of the recording material S are stored in the storage means in advance.
In addition, in the present embodiment, a change is made to the speed of the fixing rollers pair 5 after the loop detecting sensor 12 detects the loop, so that the loop length is the lower limit length when the rear end of the sheet is passed through the secondary transfer roller pair 3. However, the change speed may not necessarily be constant. In other words, it may also be acceptable that, by gradually accelerating or decelerating, the loop length will be the lower limit when the rear end of the sheet passes through the secondary transfer roller pair 3.
Although in the above embodiments, it is exemplified that the image forming apparatus that uses the 4 image-forming portions for forming color images, the number of the portions to be used shall not be limited, and may be set appropriately, as necessary.
In addition, in the above embodiments although the printer is exemplified as the image forming apparatus, the present invention shall not be limited to this, and it may be an image forming apparatus that uses other image forming apparatus such as a copying machine or facsimile machine or the like, a complex machine that combines these functions, or an image forming apparatus which uses a recording material bearing member, and sequentially superimposes and transfers toner images of respective colors on recording material born by the recording bearing member, or an image forming apparatus that uses a drum-shaped intermediate transfer member instead of a belt-shaped intermediate transfer member, sequentially superimposes and transfers toner images of respective colors onto the intermediate transfer member, and collectively transfers the toner images born by the intermediate transfer member to the recording material. Application of the present invention to the image forming apparatus can achieve similar effect.
This application claims the benefit of Japanese Application No. 2005-097089 filed on Mar. 30, 2005 hereby incorporated by reference herein in its entirety.
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