IMAGE FORMING APPARATUS

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2022-103392 filed Jun. 28, 2022.

BACKGROUND
(i) Technical Field

The present disclosure relates to an image forming apparatus.

(ii) Related Art

Japanese Patent No. 3292954 discloses a printer that forms an image on a print surface of a disc that is placed on a transport table and is transported by transferring a toner image given to a transfer belt onto the print surface.

SUMMARY

Some image forming apparatuses transfer an image onto a recording medium by bringing a transfer unit into contact with the recording medium that is transported.

In such image forming apparatuses, a support unit such as a jig that supports a recording medium may be provided in order to keep misregistration of the recording medium from occurring due to a shock caused when the transfer unit makes contact with the recording medium. However, in a case where a recording medium whose height changes from a front end toward a rear end in a transport direction is supported by a support unit, a region where an image can be formed on the recording medium may undesirably become narrow.

Aspects of non-limiting embodiments of the present disclosure relate to a technique of keeping a region where an image can be formed on a recording medium from becoming narrow as compared with a case where contact of a transfer unit with an image formation surface is hindered by a support unit that supports the recording medium.

Aspects of certain non-limiting embodiments of the present disclosure overcome the above disadvantages and/or other disadvantages not described above. However, aspects of the non-limiting embodiments are not required to overcome the disadvantages described above, and aspects of the non-limiting embodiments of the present disclosure may not overcome any of the disadvantages described above.

According to an aspect of the present disclosure, there is provided an image forming apparatus including: a transport unit that transports a recording medium having an image formation surface whose height changes from a front end toward a rear end; a transfer unit that transfers an image onto the image formation surface of the recording medium transported by the transport unit by making contact with the image formation surface; and a support unit that supports the recording medium without hindering contact of the transfer unit with the image formation surface and is transported together with the recording medium by the transport unit.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the present disclosure will be described in detail based on the following figures, wherein:

FIG. 1 illustrates a configuration of an image forming apparatus to which the present exemplary embodiment is applied;

FIG. 2 illustrates a configuration of a transfer unit;

FIGS. 3A to 3C illustrate operation of a transport mechanism before start of image formation by the transfer unit, and FIG. 3A illustrates how the height is controlled, FIG. 3B illustrates a state where an attachment table has retreated to a preparation position after the height control, and FIG. 3C illustrates a state where the transfer unit starts transfer of an image;

FIGS. 4A and 4B illustrate a configuration and operation of a fixing unit, and FIG. 4A illustrates a state where openings of the fixing unit are closed, and FIG. 4B illustrates a state where the openings of the fixing unit are opened;

FIG. 5 illustrates an example of a shape of a medium on which an image is to be formed by the image forming apparatus according to the present exemplary embodiment and is a perspective view of the medium;

FIGS. 6A and 6B illustrate a jig and a medium to which the first exemplary embodiment is applied, and FIG. 6A is a view of the jig and the medium viewed from an upper side, and FIG. 6B is a cross-sectional view of the jig and the medium taken along a transport direction at a central part in a width direction;

FIGS. 7A and 7B illustrate a jig and a medium to which a second exemplary embodiment is applied, and FIG. 7A is a view of the jig and the medium viewed from an upper side, and FIG. 7B is a cross-sectional view of the jig and the medium taken along a transport direction at a central part in a width direction; and

FIG. 8 is a view for explaining a comparative example for the present exemplary embodiment and illustrates a state where contact of an intermediate transfer belt with a front surface of a medium is hindered by a jig.

DETAILED DESCRIPTION
First Exemplary Embodiment

Exemplary embodiments of the present disclosure are described in detail below with reference to the attached drawings. An image forming apparatus according to the present exemplary embodiments is an image forming apparatus employing digital printing. Although an electrophotographic system, an inkjet system, and the like are known as digital printing systems, the electrophotographic system is assumed in the present exemplary embodiments. In the electrophotographic system, a transfer unit and a medium are brought into contact with each other when an image is transferred onto the medium. Furthermore, in the present exemplary embodiments, any of media having various thicknesses and shapes such as metal, glass, and tile is assumed as an object on which an image is to be printed.

Apparatus Configuration

FIG. 1 illustrates a configuration of an image forming apparatus to which the present exemplary embodiment is applied. The image forming apparatus 10 includes a transfer unit 100, a fixing unit 200, a medium attaching detaching unit 300, and a transport mechanism 400. Furthermore, the image forming apparatus 10 includes a controller having one or more processors, which are computing units, a memory serving as a working region in data processing, and a storage device that holds a program and data. Although the controller is a single controller that controls operation of the whole image forming apparatus 10 in this example, the controller may be controllers individually provided in units such as the transfer unit 100, the fixing unit 200, and the transport mechanism 400.

The transfer unit 100 is a unit that transfers an image formed with particles such as toner onto a recording medium 500 (hereinafter simply referred to as a medium 500). The fixing unit 200 is a unit that fixes, on a surface of the medium 500, an image transferred by the transfer unit 100 by heating the medium 500. The medium attaching detaching unit 300 is a unit in which a user of the image forming apparatus 10 attaches the medium 500 to an attachment table (described later) provided in the transport mechanism 400. The transport mechanism 400 is provided across the transfer unit 100, the fixing unit 200, and the medium attaching detaching unit 300, and transports the medium 500 on which an image is to be printed to the units 100, 200, and 300 as indicated by the arrow in FIG. 1.

Configuration of Transfer Unit 100

FIG. 2 illustrates a configuration of the transfer unit 100. The transfer unit 100 forms an image with charged particles and transfers the image onto the medium 500 by generating an electric field. The transfer unit 100 includes a developing device 110, a first transfer roll 120, and an intermediate transfer belt 131. The intermediate transfer belt 131 is tensioned between the developing device 110 and a position where an image is transferred onto the medium 500 by rollers 132 and 133 and a backup roll 140. Furthermore, the transfer unit 100 includes a cleaning device 150 for removing particles attached to the intermediate transfer belt 131. Furthermore, the transfer unit 100 includes a power source 160 that applies a predetermined voltage to the backup roll 140.

The developing device 110 is a unit that forms, on a photoreceptor, an electrostatic latent image of an image to be transferred and develops the image by attaching charged particles to the electrostatic latent image on the photoreceptor. As the developing device 110, an existing device used in an electrophotographic image forming apparatus can be used. FIG. 2 illustrates an example of a configuration employed in a case where color image formation processing is performed by using four colors, that is, three colors: yellow, magenta, and cyan, and an additional one color: black. The developing device 110 is provided for each of these colors, and the developing devices 110 for yellow, magenta, cyan, and black are given alphabets (color signs) Y, M, C, and K indicative of the colors in FIG. 2. In the following description, the suffixes are omitted in a case where the colors of the developing devices 110 need not be distinguished although the suffixes Y, M, C, and K are given to the reference signs in a case where the colors are distinguished.

The first transfer roll 120 is a unit used to transfer (first transfer) an image formed by the developing device 110 onto the intermediate transfer belt 131. The first transfer roll 120 is disposed so as to face the photoreceptor of the developing device 110, and the intermediate transfer belt 131 is located between the developing device 110 and the first transfer roll 120. The first transfer roll 120 is provided corresponding to each of the developing devices 110Y, 110M, 110C, and 110K. In FIG. 2, the first transfer rolls 120 corresponding to the developing devices 110Y, 110M, 110C, and 110K of the respective colors are given alphabets (color signs) Y, M, C, and K indicative of the colors. In the following description, the suffixes are omitted in a case where the colors of the first transfer rolls 120 need not be distinguished although the suffixes Y, M, C, and K are given to the reference signs in a case where the colors are distinguished.

The intermediate transfer belt 131, the rollers 132 and 133, and the backup roll 140 are units used to transfer an image formed by the developing device 110 onto the medium 500. As illustrated in FIG. 2, the intermediate transfer belt 131 rotates in a direction indicated by the arrows in FIG. 2 (a counterclockwise direction in the example illustrated in FIG. 2) while being suspended around the rollers 132 and 133 and the backup roll 140 in a tensioned state. For example, one or both of the rollers 132 and 133 is(are) a roller(s) that is(are) driven to rotate, and the intermediate transfer belt 131 is pulled by rotation of this(these) roller(s). In this way, the intermediate transfer belt 131 rotates.

An outer surface of the intermediate transfer belt 131 in the example of the configuration in FIG. 2 is a surface (hereinafter referred to as a “transfer surface”) on which an image is held. An image is transferred from the photoreceptor of the developing device 110 onto the transfer surface of the intermediate transfer belt 131 when the intermediate transfer belt 131 passes between the developing device 110 and the first transfer roll 120. In the example of the configuration illustrated in FIG. 2, images of the respective colors: yellow (Y), magenta (M), cyan (C), and black (K) are superimposed on the transfer surface by the developing devices 110Y, 110M, 110C, and 110K and the first transfer rolls 120Y, 120M, 120C, and 120K, and thus a multi-color image is formed.

The backup roll 140 transfers (second transfer) the image onto the medium 500 by bringing the transfer surface of the intermediate transfer belt 131 into contact with the medium 500. A predetermined voltage is applied to the backup roll 140 by the power source 160 when the image is transferred. This generates an electric field (hereinafter referred to as a “transfer electric field”) in a range including the backup roll 140 and the medium 500, thereby transferring the image formed with charged particles from the intermediate transfer belt 131 onto the medium 500. As described above, to transfer an image from the intermediate transfer belt 131 onto the medium 500, an electric current need to flow from the backup roll 140 to the medium 500 through the intermediate transfer belt 131. In a case where the medium 500 is a conductor such as a metal, an electric current flows through the medium 500 itself, and therefore an image is transferred onto a surface of the medium 500 by generating a transfer electric field. On the other hand, in a case where the medium 500 is not a conductor, no electric current flows through the medium 500, and therefore an image cannot be transferred in this state. In view of this, in a case where the medium 500 is not a conductor, an electric current is passed through the medium 500 by taking a measure such as forming a layer made of an electrically conductive material (hereinafter referred to as an “electrically conductive layer”) in advance in at least a region on the surface of the medium 500 where an image is to be formed.

A procedure of transfer of an image by the intermediate transfer belt 131 is described. When the intermediate transfer belt 131 rotates, images of the respective colors: yellow (Y), magenta (M), cyan (C), and black (K) are sequentially superimposed on the transfer surface (outer surface in FIG. 2) of the intermediate transfer belt 131 by the developing devices 110Y, 110M, 110C, and 110K and the first transfer rolls 120Y, 120M, 120C, and 120K, and thus a multi-color image is formed. When the intermediate transfer belt 131 further rotates, the image formed on the transfer surface of the intermediate transfer belt 131 reaches a position (hereinafter referred to as a “transfer position”) where the intermediate transfer belt 131 makes contact with the medium 500. As described above, a voltage is applied to the backup roll 140. This generates a transfer electric field, thereby transferring the image from the intermediate transfer belt 131 onto the medium 500.

The cleaning device 150 is a unit that removes particles attached to the transfer surface of the intermediate transfer belt 131. The cleaning device 150 is provided at a position on a downstream side relative to the transfer position and an upstream side relative to the developing device 110Y and the first transfer roll 120Y in a direction in which the intermediate transfer belt 131 rotates. With this configuration, particles remaining on the transfer surface of the intermediate transfer belt 131 are removed by the cleaning device 150 after the image is transferred from the intermediate transfer belt 131 onto the medium 500. In a next operation cycle, an image is newly transferred (first transfer) onto the transfer surface from which particles have been removed.

Configuration of Transport Mechanism 400 and Attachment Structure for Attachment of Medium 500

An attachment structure for attachment of the medium 500 is described. In the present exemplary embodiment, it is assumed that the medium 500 can have various thicknesses and shapes. In a case where the medium 500 directly placed on a transport path constituted by a belt and a roller is transported, it is difficult to bring the intermediate transfer belt 131 into contact with the medium 500 in a predetermined relationship since a height of the medium 500 relative to the transport path varies at the transfer position of the transfer unit 100 in a case where a thickness and a shape of the medium 500 vary. Specifically, such a situation can occur in which the medium 500 does not make contact with the intermediate transfer belt 131 in a case where the height of the medium 500 is low, and a strong shock is caused when the medium 500 makes contact with the intermediate transfer belt 131 in a case where the height of the medium 500 is high. In view of this, the transport mechanism 400 according to the present exemplary embodiment has the attachment table 420 having a height adjuster and transports the medium 500 placed on the attachment table 420 together with the attachment table 420.

The transport mechanism 400 includes the transport rail 410 that specifies a transport path for the medium 500 and the attachment table 420 that moves on the transport rail 410 (see FIG. 2). The attachment table 420 includes a leg part 421 attached to the transport rail 410 and a table part 422 on which the medium 500 is to be placed. Furthermore, a jig 430 that holds the medium 500 on the table part 422 is attached to the table part 422. Note that the transport rail 410 and the attachment table 420 are an example of a transport unit.

In the example of the configuration illustrated in FIG. 1, the transport rail 410 is disposed so as to extend from the medium attaching detaching unit 300 to the transfer unit 100 while passing the fixing unit 200. An end portion of the transport rail 410 on a medium attaching detaching unit 300 side is the transport start position and the transport end position. The attachment table 420 is transported leftward in FIG. 1 from the transport start position of the medium attaching detaching unit 300, and an image is transferred onto the medium 500 in the transfer unit 100. Then, the attachment table 420 is transported rightward in FIG. 1, and reaches the transport end position of the medium attaching detaching unit 300 after the image is fixed on the medium 500 in the fixing unit 200.

The leg part 421 is attached to the transport rail 410 and moves on the transport rail 410. A mechanism for moving the leg part 421 on the transport rail 410 is not limited in particular. For example, the leg part 421 may be provided with a driving device so as to be movable on its own or the transport rail 410 may be provided with a unit that pulls the leg part 421. Furthermore, the leg part 421 has a height controller that controls a height of the table part 422. A configuration of the height controller is not limited in particular. For example, the table part 422 may be moved up and down by rack and pinion and a drive motor. Alternatively, the height of the table part 422 may be controlled by manually operating a gear that is linked with the height of the table part 422. Furthermore, various methods can be used as an operation method for controlling the height. For example, an input interface for input to a controller of the drive motor may be prepared, and an operator of the image forming apparatus 10 may manually input and set height data by using the input interface. Alternatively, the height of the medium 500 attached to the attachment table 420 may be automatically detected by using a sensor, and the drive motor may be controlled so that the medium 500 is located at an appropriate height.

The table part 422 is a table that is attached to the leg part 421 and on which the medium 500 is placed with the jig 430 interposed therebetween. The table part 422 is provided with a fastener (not illustrated) for positioning the jig 430. Any jigs 430 compatible with this fastener can be positioned and attached to the table part 422 irrespective of shapes thereof.

Furthermore, the table part 422 is attached so as to float up and sink down with respect to the leg part 421 in accordance with a pressure applied from an upper side. The configuration in which the table part 422 floats up and sinks down is, for example, realized by interposing an elastic body at a portion where the table part 422 and the leg part 421 are joined. By employing such a configuration, a shock caused when the medium 500 held by the jig 430 attached to the table part 422 makes contact with the intermediate transfer belt 131 of the transfer unit 100 is lessened.

The table part 422 according to the present exemplary embodiment is made of an electrically conductive material. Furthermore, the table part 422 is in contact with a grounding member (not illustrated) and is connected to ground with the grounding member interposed therebetween.

The jig 430 is an example of a support unit and is a device that holds the medium 500 and is attached to the table part 422. A portion of the jig 430 attached to the table part 422 has a shape and a structure compatible with the fastener of the table part 422. Furthermore, the jig 430 has a shape for holding the medium 500. Therefore, media 500 having various shapes and sizes can be placed on the attachment table 420 by preparing jigs 430 compatible with the shapes and sizes of the media 500.

The jig 430 according to the present exemplary embodiment is made of an electrically conductive material. Furthermore, the portion of the jig 430 attached to the table part 422 is conductive with the table part 422. Furthermore, the jig 430 supports the medium 500 so as to be conductive with a surface (an image formation surface, which will be described later) of the medium 500 including a region where an image is to be formed. In this way, the image formation surface of the medium 500 supported by the jig 430 is connected to ground with the jig 430 and the table part 422 interposed therebetween.

Note that a relationship between the jig 430 and the medium 500 will be described in detail later.

Preliminary Operation of Image Formation

The image forming apparatus 10 according to the present exemplary embodiment has the transport mechanism 400 configured as above and therefore can print an image on any of the media 500 having various shapes and sizes. However, before start of image transfer operation, the height of the table part 422 is controlled in order to prevent a strong shock from being caused by contact of the medium 500 with the intermediate transfer belt 131 of the transfer unit 100 or prevent failure to bring the medium 500 into contact with the intermediate transfer belt 131 when an image is transferred onto the medium 500.

FIGS. 3A to 3C illustrate operation of the transport mechanism 400 before start of image formation by the transfer unit 100. FIG. 3A illustrates how the height is controlled, FIG. 3B illustrates a state where the attachment table 420 has retreated to a preparation position after the height control, and FIG. 3C illustrates a state where the transfer unit 100 starts transfer of an image.

In a case where an image is formed on the medium 500, first, the medium 500 held by the jig 430 is placed on the attachment table 420 at the transport start position of the medium attaching detaching unit 300. Then, the medium 500 is lowered to a height at which the medium 500 does not make contact with the intermediate transfer belt 131 of the transfer unit 100 by the height controller of the attachment table 420, and then the attachment table 420 on which the medium 500 is placed is moved to a position below the transfer position of the transfer unit 100.

Next, the height of the attachment table 420 is controlled so that the medium 500 makes contact with the intermediate transfer belt 131 with a strength appropriate for transfer of the image at the transfer position (arrow a in FIG. 3A). When the height is controlled, information on an appropriate height (hereinafter referred to as a “transfer execution height”) thus obtained is held, for example, in a memory of a controller 600 (see FIG. 1). Then, the attachment table 420 is lowered to a height where the medium 500 does not make contact with the intermediate transfer belt 131 and moves to the preparation position for transfer operation (arrow b in FIG. 3A).

When the attachment table 420 moves to the preparation position, the height of the attachment table 420 is adjusted to the transfer execution height on the basis of the information obtained in the height control. Then, the attachment table 420 moves to the transfer position (arrow c in FIG. 3B), and transfer of the image starts when the medium 500 makes contact with the intermediate transfer belt 131 at the transfer position (FIG. 3C).

Configuration of Fixing Unit 200

After the image is transferred onto the medium 500 in the transfer unit 100, the image is fixed in the fixing unit 200. In the present exemplary embodiment, an image is formed on any of the media 500 having various thicknesses and shapes, and therefore the fixing processing is performed by a non-contact-type device. The fixing unit 200 melts particles forming the image transferred onto the medium 500 by heating the particles and thereby fixes the particles on the surface of the medium 500.

FIGS. 4A and 4B illustrate a configuration and operation of the fixing unit 200. FIG. 4A illustrates a state where openings of the fixing unit 200 are closed, and FIG. 4B illustrates a state where the openings of the fixing unit 200 are opened. The fixing unit 200 includes a carry-in opening 201, which is an opening through which the medium 500 is carried into the fixing unit 200, and a carry-out opening 202, which is an opening through which the medium 500 is carried out of the fixing unit 200. Furthermore, the carry-in opening 201 and the carry-out opening 202 of the fixing unit 200 according to the present exemplary embodiment are provided with an opening and closing member and are configured to be opened when the medium 500 is carried into or out of the fixing unit 200 and be closed when the fixing processing is performed.

The fixing unit 200 includes a heat source 210 for thermal fixation. The heat source 210 can be, for example, any of various existing heat sources such as a halogen lamp, a ceramic heater, and an infrared lamp. Instead of the heat source 210, a device that heats particles forming the image by emitting infrared laser may be used. The fixing unit 200 according to the present exemplary embodiment is provided with a member that can cover the heat source 210, and is configured so that the heat source 210 is exposed when the fixing processing is performed.

In the example illustrated in FIGS. 4A and 4B, roll-up shutters 220 and 230 are provided as the opening and closing members of the carry-in opening 201 and the carry-out opening 202. The shutters 220 and 230 are closed (see FIG. 4A) except when the medium 500 is carried into and out of the fixing unit 200 and thereby prevent a decrease in internal temperature. The shutter 220 of the carry-in opening 201 opens when the medium 500 is carried into the fixing unit 200, and the shutter 230 of the carry-out opening 202 opens when the medium 500 is carried out of the fixing unit 200 (see FIG. 4B).

In the example illustrated in FIGS. 4A and 4B, a roll-up shutter 240 is provided as the covering member that covers the heat source 210. The shutter 240 closes in a case where the shutter 220 of the carry-in opening 201 and/or the shutter 230 of the carry-out opening 202 open(s) (see FIG. 4B). This may keep a decrease in temperature of the heat source 210 small even in a case where the carry-in opening 201 and/or the carry-out opening 202 open(s) and the internal temperature decreases.

In the example illustrated in FIG. 4B, a state where both of the shutter 220 of the carry-in opening 201 and the shutter 230 of the carry-out opening 202 are opened is illustrated for convenience of description. In actual operation, the shutter 230 of the carry-out opening 202 remains closed when the medium 500 is carried into the fixing unit 200, and the shutter 220 of the carry-in opening 201 remains closed when the medium 500 is carried out of the fixing unit 200. This keeps a decrease in internal temperature small.

The shutters 220, 230, and 240 illustrated in FIGS. 4A and 4B are an example of the opening and closing members of the carry-in opening 201 and the carry-out opening 202 and the covering member of the heat source 210. The opening and closing members and covering member are not limited to the above configuration, as long as the opening and closing members and covering member keep a decrease in internal temperature of the fixing unit 200 and temperature of the heat source 210 small. For example, an opening and closing door may be provided instead of the shutters 220, 230, and 240 illustrated in FIGS. 4A and 4B. As the opening and closing member of the carry-out opening 202 through which the medium 500 passes after the fixing processing is finished, a curtain made of a heat insulating material or air curtain may be used to prevent leakage of internal air.

Configuration of Medium Attaching Detaching Unit 300

See FIG. 1 again. As described above, the medium attaching detaching unit 300 is a unit that is located at the transport start position and the transport end position, which are an end portion of the transport rail 410. In the medium attaching detaching unit 300, the jig 430 is attached and detached to and from the attachment table 420 or the medium 500 is attached and detached to and from the jig 430 attached to the attachment table 420.

Furthermore, the medium attaching detaching unit 300 according to the present exemplary embodiment includes a cleaning device 350, which is an example of a cleaning unit, for removing particles attached to an upper surface 431 (see FIG. 5, which will be described later) of the jig 430. The cleaning device 350 has, for example, a brush, a web, or the like that makes contact with the upper surface 431 of the jig 430.

After an image is fixed on the medium 500 in the fixing unit 200, the attachment table 420 on which the jig 430 holding the medium 500 is placed moves to the transport end position of the medium attaching detaching unit 300. At the transport end position of the medium attaching detaching unit 300, the medium 500 is removed from the jig 430 attached to the attachment table 420. Then, the particles attached to the upper surface 431 of the jig 430 are removed by the cleaning device 350.

Then, a new medium 500 is placed on the jig 430, and image formation operation on this new medium 500 is performed.

As described above, in the image forming apparatus according to the present exemplary embodiment, an image formed with particles is transferred from the transfer surface of the intermediate transfer belt 131 onto the medium 500 by bringing the transfer surface of the intermediate transfer belt 131 into contact with the medium 500 held by the jig 430. During this process, the transfer surface of the intermediate transfer belt 131 and the upper surface 431 of the jig 430 sometimes make contact with each other, and particles are sometimes attached from the intermediate transfer belt 131 to the upper surface 431 of the jig 430. In a case where particles are attached to the upper surface 431 of the jig 430, the particles are sometimes attached to a new medium 500 and smear the new medium 500 when the new medium 500 is placed on the jig 430 after image formation operation on the medium 500 is finished.

In the present exemplary embodiment, the particles attached to the jig 430 are removed by the cleaning device 350, and therefore it is less likely that the particles are attached to and smear the medium 500 placed on the jig 430.

Shape of Medium 500

In the image forming apparatus 10 according to the present exemplary embodiment, it is assumed that the medium 500 on which an image is to be printed can have various thicknesses and shapes, as described above.

FIG. 5 illustrates an example of a shape of the medium 500 on which an image is to be formed by the image forming apparatus 10 according to the present exemplary embodiment and is a perspective view of the medium 500.

The medium 500 has a front surface 510 and a rear surface 520 that are curved so as to protrude upward and have a rectangular shape when viewed from an upper side, a pair of first side surfaces 530 that connect opposed sides of the front surface 510 and the rear surface 520, and a pair of second side surfaces 540 that connect opposed sides of the front surface 510 and the rear surface 520, and has a plate shape curved so as to protrude upward as a whole. In this example, the front surface 510 of the medium 500 is the image formation surface including the region where an image is to be formed. The whole medium 500 including the front surface 510, which is the image formation surface, is made of a conductor.

The medium 500 having a shape like the one illustrated in FIG. 5 is, for example, attached to the jig 430 (see FIG. 1) so that the first side surfaces 530 extend along a transport direction in which the medium 500 is transported by the transport mechanism 400. Specifically, the medium 500 is attached to the jig 430 so that the rear surface 520 faces downward.

In the following description, the transport direction means a transport direction (a direction indicated by arrow c in FIG. 3B) in which the attachment table 420, the medium 500 attached to the attachment table 420, or the like is transported from the preparation position to the transport end position while passing the transfer position.

In a case where the medium 500 is attached to the jig 430 so that the first side surfaces 530 extend along the transport direction in which the medium 500 is transported by the transport mechanism 400, one of the second side surfaces 540 is located at a front end in the transport direction, and the other one of the second side surfaces 540 is located at a rear end in the transport direction. Hereinafter, the second side surface 540 located at a front end in the transport direction and the second side surface 540 located at a rear end in the transport direction when the medium 500 is attached to the jig 430 are sometimes referred to as a front end surface 541 and a rear end surface 542, respectively.

In a case where the medium 500 is attached to the jig 430, a height of the front surface 510, which is the image formation surface, changes from the front end toward the rear end in the transport direction. Specifically, the height of the front surface 510 of the medium 500 decreases toward the front end and the rear end in the transport direction. Specifically, since the medium 500 is curved so as to protrude upward, in a case where the medium 500 is attached to the jig 430, a height of the front end and a height of the rear end in the transport direction of the front surface 510, which is the image formation surface, (that is, a height of the front end surface 541 and a height of the rear end surface 542) are lower than a height of a central part in the transport direction of the front surface 510.

In a case where the medium 500 having the front surface 510 (image formation surface) whose height changes is attached to the jig 430 and an image is formed on the front surface 510 of the medium 500 by the image forming apparatus 10, contact of the intermediate transfer belt 131 with the front surface 510 of the medium 500 may be undesirably hindered by the jig 430 depending on a shape of the jig 430 to which the medium 500 is attached.

FIG. 8 is a view for explaining a comparative example for the present exemplary embodiment and illustrates a state where contact of the intermediate transfer belt 131 with the front surface 510 of the medium 500 is hindered by the jig 430.

In the example illustrated in FIG. 8, the jig 430 supports the medium 500 in contact with the front end surface 541, which is the front end of the medium 500 in the transport direction, and the rear end surface 542, which is the rear end of the medium 500 in the transport direction. Furthermore, a height of the upper surface 431 of the jig 430 is higher than the height of the front end surface 541 and the height of the rear end surface 542 of the medium 500. Specifically, in the example illustrated in FIG. 8, the jig 430 has a portion that protrudes upward (toward the intermediate transfer belt 131) beyond the front end surface 541 and the rear end surface 542 of the jig 430.

In this case, when the attachment table 420 moves to the transfer position in a state where the height of the attachment table 420 has been controlled so that the front surface 510 of the medium 500 makes contact with the intermediate transfer belt 131 with strength appropriate for transfer of an image, the transfer surface of the intermediate transfer belt 131 makes contact with the upper surface 431 of the jig 430 before making contact with the front surface 510 of the medium 500. In this case, the jig 430 hinders the transfer surface of the intermediate transfer belt 131 from making contact with the front end (a portion indicated by a in FIG. 8) of the front surface 510 of the medium 500.

Then, the transfer surface of the intermediate transfer belt 131 makes contact with the central part of the front surface 510 of the medium 500. After an image is transferred onto the front surface 510, the attachment table 420 further moves along the transport direction. As a result, the transfer surface of the intermediate transfer belt 131 makes contact with the upper surface 431 of the jig 430 without making contact with the rear end (a portion indicated by b in FIG. 8) of the front surface 510 of the medium 500. In this case, the jig 430 hinders the transfer surface of the intermediate transfer belt 131 from making contact with the rear end (the portion indicated by b in FIG. 8) of the front surface 510 of the medium 500.

In a case where the jig 430 hinders the intermediate transfer belt 131 from making contact with the front surface 510 of the medium 500, which is the image formation surface, an image cannot be transferred from the intermediate transfer belt 131 onto the front end and the rear end of the front surface 510 of the medium 500, and therefore a region where an image can be formed on the front surface 510 of the medium 500 becomes narrow. Furthermore, since a region where an image can be formed on the front surface 510 of the medium 500 becomes narrow, it becomes difficult to form an image having no frame (frame-less image) on the upper surface of the medium 500.

On the other hand, in the present exemplary embodiment, the jig 430 supports the medium 500 so as not to hinder the intermediate transfer belt 131 from making contact with the front surface 510, which is the image formation surface, and therefore a region where an image can be formed on the medium 500 is kept from becoming narrow.

The shape and the like of the jig 430 according to the present exemplary embodiment are described in detail below.

FIGS. 6A and 6B illustrate the jig 430 and the medium 500 to which the first exemplary embodiment is applied, and FIG. 6A is a view of the jig 430 and the medium 500 viewed from an upper side (the intermediate transfer belt 131 side), and FIG. 6B is a cross-sectional view of the jig 430 and the medium 500 taken along the transport direction at a central part in a width direction crossing the transport direction.

Note that the shape of the medium 500 is similar to that illustrated in FIG. 5.

As described above, the jig 430 holds the medium 500 and is attached to the table part 422.

The jig 430 according to the present exemplary embodiment has a flat plate part 440 that has a flat plate shape having a rectangular upper surface 441 and a rectangular lower surface 442, and the medium 500 is placed on the upper surface 441. The jig 430 is attached to the table part 422 so that the lower surface 442 of the flat plate part 440 faces the table part 422, and is conductive with the table part 422 through the lower surface 442.

Furthermore, the jig 430 has support walls 443 that protrude upward from the upper surface 441 of the flat plate part 440, extend along the transport direction, and make contact with the first side surfaces 530 of the medium 500. The medium 500 is inserted into a space between the pair of support walls 443 of the jig 430, and the medium 500 is supported by the support walls 443. As described above, the medium 500 is supported by the jig 430 so that the pair of first side surfaces 530 extend along the transport direction in which the medium 500 is transported by the transport mechanism 400 and the pair of second side surfaces 540 (the front end surface 541 and the rear end surface 542) extend along the width direction of the medium 500 orthogonal to the transport direction. The support walls 443 may be given a pressure in the width direction so as to press the first side surfaces 530 of the medium 500 although this is not illustrated. In this case, misregistration of the medium 500 in the transport direction is less likely to be caused by a shock when the attachment table 420 moves to the transfer position and the intermediate transfer belt 131 (see FIG. 2) makes contact with the medium 500.

The jig 430 according to the present exemplary embodiment does not have a portion that protrudes upward, that is, toward the intermediate transfer belt 131 beyond the front surface 510 of the medium 500, which is the image formation surface, in a case where the medium 500 is attached to the jig 430. More specifically, the height of the support walls 443 that support the first side surfaces 530 of the medium 500 is lower than the height of the front surface 510 of the medium 500, which is the image formation surface, in a case where the medium 500 is attached to the jig 430.

With this configuration, the intermediate transfer belt 131 makes contact with the front surface 510 of the medium 500 without being hindered by the jig 430 in a case where the attachment table 420 moves to the transfer position in a state where the height of the attachment table 420 has been controlled so that the front surface 510 of the medium 500 makes contact with the intermediate transfer belt 131 with strength appropriate for transfer of an image. Accordingly, an image is transferred from the intermediate transfer belt 131 onto the front surface 510 of the medium 500 from the front end to the rear end in the transport direction as the attachment table 420 is moved by the transport mechanism 400.

As described above, in the present exemplary embodiment, the jig 430 does not have a portion that protrudes toward the intermediate transfer belt 131 beyond the front surface 510 of the medium 500, which is the image formation surface, and therefore a region where an image can be formed on the front surface 510 of the medium 500 is kept from becoming narrow as compared with a case where the jig 430 has a portion that protrudes toward the intermediate transfer belt 131 beyond the front surface 510 of the medium 500.

From another perspective, the jig 430 according to the present exemplary embodiment does not make contact with the intermediate transfer belt 131 during a period in which an image is being transferred from the intermediate transfer belt 131 onto the front surface 510 of the medium 500 as the attachment table 420 is moved by the transport mechanism 400 after the attachment table 420 moves to the transfer position and the intermediate transfer belt 131 makes contact with the front end of the front surface 510 of the medium 500. This keeps a region where an image can be formed on the front surface 510 of the medium 500 from becoming narrow as compared with a case where the jig 430 makes contact with the intermediate transfer belt 131 during the period in which an image is being transferred from the intermediate transfer belt 131 onto the front surface 510 of the medium 500.

A length of the support walls 443 of the jig 430 according to the present exemplary embodiment along the transport direction is shorter than a length of the medium 500 along the transport direction. With this configuration, for example, the support walls 443 are less likely to protrude toward the front side beyond the front end surface 541 of the medium 500 or toward the rear side beyond the rear end surface 542 of the medium 500 in a case where the medium 500 is attached to the jig 430, as compared with a case where the length of the support walls 443 along the transport direction is longer than the length of the medium 500 along the transport direction. Specifically, the support walls 443 of the jig 430 according to the present exemplary embodiment support the first side surfaces 530 of the medium 500 on a rear side relative to the front end surface 541, which is the front end of the medium 500 in the transport direction.

In this case, in a case where the attachment table 420 moves to the transfer position, the intermediate transfer belt 131 is less likely to make contact with the support walls 443, and contact of the intermediate transfer belt 131 with the front surface 510 of the medium 500 is less likely to be hindered. Furthermore, a region where an image can be formed on the front surface 510 of the medium 500 is kept from becoming narrow.

Furthermore, the jig 430 according to the present exemplary embodiment does not support the front end surface 541, which is the front end of the medium 500 in the transport direction. The jig 430 does not make contact with the intermediate transfer belt 131 before the intermediate transfer belt 131 makes contact with the front end of the medium 500. As a result, contact of the intermediate transfer belt 131 with the front end of the front surface 510 of the medium 500 is less likely to be hindered in a case where the attachment table 420 moves to the transfer position. Furthermore, a region where an image can be formed on the front surface 510 of the medium 500 is further kept from becoming narrow.

Furthermore, the jig 430 according to the present exemplary embodiment does not support the rear end surface 542, which is the rear end of the medium 500 in the transport direction. As a result, contact of the intermediate transfer belt 131 with the rear end of the front surface 510 of the medium 500 is less likely to be hindered in a case where the attachment table 420 moves to the transfer position. Furthermore, a region where an image can be formed on the front surface 510 of the medium 500 is further kept from becoming narrow.

As described above, the height of the front surface 510 of the medium 500 attached to the jig 430 according to the present exemplary embodiment decreases toward the front end in the transport direction. In this case, in a case where the attachment table 420 moves to the transfer position and the intermediate transfer belt 131 makes contact with the front end of the front surface 510 of the medium 500, a pressure applied from the intermediate transfer belt 131 to the medium 500 is smaller than in a case where the height of the front surface 510 does not decrease toward the front end in the transport direction.

Furthermore, the height of the front surface 510 of the medium 500 gradually increases from the front end toward a rear side in the transport direction. Accordingly, the pressure applied from the intermediate transfer belt 131 to the medium 500 gradually increases as the attachment table 420 further moves in the transport direction after the intermediate transfer belt 131 makes contact with the front end of the front surface 510 of the medium 500.

With this configuration, a shock given to the medium 500 when the intermediate transfer belt 131 makes contact with the front end of the medium 500 is more likely to be lessened than in a case where the height of the front surface 510 of the medium 500 does not decrease toward the front end in the transport direction.

Therefore, even in a case where the jig 430 does not support the front end surface 541 and the rear end surface 542 of the medium 500, misregistration of the medium 500 is less likely to be caused by a shock given to the medium 500 when the intermediate transfer belt 131 makes contact with the front end of the medium 500.

Second Exemplary Embodiment

Next, a second exemplary embodiment of the present disclosure is described below. Note that constituent elements similar to those in the first exemplary embodiment are given identical reference signs, and detailed description thereof is omitted.

FIGS. 7A and 7B illustrate a jig 430 and a medium 500 to which the second exemplary embodiment is applied, and FIG. 7A is a view of the jig 430 and the medium 500 viewed from an upper side (intermediate transfer belt 131 side), and FIG. 7B is a cross-sectional view of the jig 430 and the medium 500 taken along a transport direction at a central part in a width direction.

The jig 430 according to the present exemplary embodiment has a rectangular upper surface 431 that faces the intermediate transfer belt 131 when transported to a transfer position and a rectangular lower surface 432 opposite to the upper surface 431, and has a rectangular parallelepiped shape as a whole. The jig 430 is attached to a table part 422 so that the lower surface 432 faces the table part 422, and is conductive with the table part 422 through the lower surface 432.

Furthermore, the jig 430 has, in a central part thereof in the transport direction in which the medium 500 is transported by a transport mechanism 400, a recessed part 435 that is recessed from the upper surface 431 toward the lower surface 432. The medium 500 is inserted into a space formed inside the recessed part 435 of the jig 430, and thus the medium 500 is supported in the recessed part 435. The medium 500 is inserted into the recessed part 435 so that first side surfaces 530 extend along the transport direction in which the medium 500 is transported by the transport mechanism 400.

The recessed part 435 of the jig 430 has an inner peripheral surface that matches a shape of the medium 500. Specifically, the recessed part 435 has a pair of first inner peripheral surfaces 436 that extend along the transport direction of the transport mechanism 400 and face each other with the space in the recessed part 435 interposed therebetween and a pair of second inner peripheral surfaces 437 that extend along a width direction orthogonal to the transport direction of the transport mechanism 400 and face each other with the space in the recessed part 435 interposed therebetween. Furthermore, the recessed part 435 has a bottom surface 438 extending from lower ends of the first inner peripheral surfaces 436 and the second inner peripheral surfaces 437 along the transport direction and the width direction.

In the recessed part 435, a length of each of the first inner peripheral surfaces 436 along the transport direction, in other words, an interval between the second inner peripheral surfaces 437 that face each other is equal to a length of the medium 500 in the transport direction. Furthermore, in the recessed part 435, a length of each of the second inner peripheral surfaces 437 along the width direction, in other words, an interval between the first inner peripheral surfaces 436 that face each other is equal to a length of the medium 500 along the width direction.

When the medium 500 is inserted into the recessed part 435, the jig 430 supports the first side surfaces 530, a front end surface 541, and a rear end surface 542, which are side surfaces of the medium 500. Specifically, when the medium 500 is inserted into the recessed part 435 of the jig 430, the first inner peripheral surfaces 436 of the recessed part 435 of the jig 430 make contact with the first side surfaces 530 of the medium 500. Furthermore, the second inner peripheral surfaces 437 of the recessed part 435 of the jig 430 make contact with the front end surface 541 and the rear end surface 542 of the medium 500. Furthermore, the bottom surface 438 of the recessed part 435 of the jig 430 makes contact with a rear surface 520 of the medium 500.

In the present exemplary embodiment, when the medium 500 is inserted into the recessed part 435 and the jig 430 and the medium 500 make contact with each other, the jig 430 and the medium 500 become conductive with each other. Accordingly, a front surface 510 of the medium 500, which is an image formation surface, is connected to ground with the jig 430 and the table part 422 interposed therebetween.

A height of the recessed part 435 of the jig 430 according to the present exemplary embodiment from the bottom surface 438 to the upper surface 431 is lower than a height of the front end surface 541 and the rear end surface 542 of the medium 500. Specifically, a height of the second inner peripheral surfaces 437 of the jig 430 that support the medium 500 in contact with the front end surfaces 541 and the rear end surface 542 is lower than the height of the front end surface 541 and the rear end surface 542.

With the configuration, the intermediate transfer belt 131 makes contact with the front surface 510 of the medium 500 without being hindered by the jig 430 in a case where an attachment table 420 moves to the transfer position in a state where a height of the attachment table 420 has been controlled so that the front surface 510 of the medium 500 makes contact with the intermediate transfer belt 131 with strength appropriate for transfer of an image. As the attachment table 420 is moved by the transport mechanism 400, an image is transferred from the intermediate transfer belt 131 onto the front surface 510 of the medium 500 from a front end to a rear end in the transport direction.

As described above, in the present exemplary embodiment, a region where an image can be formed on the front surface 510 of the medium 500 is kept from becoming narrow as compared with a case where the height of the second inner peripheral surfaces 437 that support the medium 500 in contact with the front end surface 541 and the rear end surface 542 of the medium 500 is higher than the height of the front end surface 541 and the rear end surface 542.

Furthermore, as in the first exemplary embodiment, the jig 430 according to the present exemplary embodiment does not make contact with the intermediate transfer belt 131 during a period in which an image is being transferred from the intermediate transfer belt 131 onto the front surface 510 of the medium 500 as the attachment table 420 is moved by the transport mechanism 400 after the attachment table 420 moves to the transfer position and the intermediate transfer belt 131 makes contact with the front end of the front surface 510 of the medium 500. As a result, a region where an image can be formed on the front surface 510 of the medium 500 is kept from becoming narrow as compared with a case where the jig 430 makes contact with the intermediate transfer belt 131 during the period in which an image is being transferred from the intermediate transfer belt 131 onto the front surface 510 of the medium 500.

Furthermore, the jig 430 according to the present exemplary embodiment supports the medium 500 in contact with the front end surface 541, which is the front end of the medium 500 in the transport direction, and the rear end surface 542, which is the rear end of the medium 500 in the transport direction, unlike the first exemplary embodiment. In other words, the jig 430 according to the present exemplary embodiment supports the medium 500 in the transport direction.

With this configuration, misregistration of the medium 500 in the transport direction is less likely to be caused by a shock given to the medium 500 when the intermediate transfer belt 131 makes contact with the front end of the medium 500 than in a case where the jig 430 does not support the front end surface 541 or the rear end surface 542 of the medium 500.

The exemplary embodiments of the present disclosure have been described above, but the technical scope of the present disclosure is not limited to the above exemplary embodiments.

For example, although the image forming apparatus 10 is configured such that a transfer electric field is formed between the backup roll 140 and the image formation surface of the medium 500 by connecting the image formation surface of the medium 500 to ground with the jig 430 interposed therebetween and applying a predetermined voltage to the backup roll 140 by the power source 160 in the above exemplary embodiment, this is not restrictive. For example, the image forming apparatus 10 may form a transfer electric field between the backup roll 140 and the image formation surface of the medium 500 by connecting the backup roll 140 to ground and applying a voltage to the jig 430 or the table part 422.

In the present exemplary embodiment, it is desirable that the configuration of the jig 430 attached to the attachment table 420 be simple since the attachment table 420 of the transport mechanism 400 moves along the transport rail 410. In a case where the configuration in which the image formation surface of the medium 500 is connected to ground with the jig 430 interposed therebetween and a predetermined voltage is applied to the backup roll 140 by the power source 160 is employed as in the above exemplary embodiments, it is unnecessary to connect a member such as a power source to the jig 430. This may simplify the configuration of the jig 430 and the configuration of the attachment table 420 to which the jig 430 is attached.

Furthermore, although a case where the medium 500 whose front surface 510, which is the image formation surface, is a curved surface protruding upward is used has been illustrated in the above exemplary embodiments, the shape of the medium 500 is not limited to this. The medium 500 is not limited to a specific shape as long as the height of the front surface 510, which is the image formation surface, changes from the front end toward the rear end in the transport direction in a case where the medium 500 is attached to the jig 430. For example, the medium 500 may have a shape such that the height of the front surface 510 gradually increases from the front end toward the rear end or may have a shape such that the height of the front surface 510 gradually decreases from the front end toward the rear end. Furthermore, the front surface 510 of the medium 500 may be a curved surface whose height continuously and gradually changes as in the present exemplary embodiment, may be a flat surface, or may be a combination of a flat surface and a curved surface.

Various changes and substitution of the configurations are encompassed within the present disclosure without departing from the scope of the technical idea of the present disclosure.

The foregoing description of the exemplary embodiments of the present disclosure has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in the art. The embodiments were chosen and described in order to best explain the principles of the disclosure and its practical applications, thereby enabling others skilled in the art to understand the disclosure for various embodiments and with the various modifications as are suited to the particular use contemplated. It is intended that the scope of the disclosure be defined by the following claims and their equivalents.

APPENDIX

(((1)))

An image forming apparatus including:

a transport unit that transports a recording medium having an image formation surface whose height changes from a front end toward a rear end;

a transfer unit that transfers an image onto the image formation surface of the recording medium transported by the transport unit by making contact with the image formation surface; and

a support unit that supports the recording medium without hindering contact of the transfer unit with the image formation surface and is transported together with the recording medium by the transport unit.

(((2)))

The image forming apparatus according to (((1))), wherein:

the support unit does not have a portion that protrudes toward the transfer unit beyond the image formation surface.

(((3)))

The image forming apparatus according to (((1))) or (((2))), wherein:

the support unit supports a side surface of the recording medium that crosses the image formation surface and extends along a transport direction in which the recording medium is transported by the transport unit, and has a height equal to or lower than a height of the image formation surface of the recording medium.

(((4)))

The image forming apparatus according to (((3))), wherein:

a length of the support unit along the transport direction is shorter than a length of the recording medium along the transport direction.

(((5)))

The image forming apparatus according to (((3))) or (((4))), wherein:

the support unit supports the side surface of the recording medium on a rear side relative to the front end of the recording medium in the transport direction.

(((6)))

The image forming apparatus according to any one of (((3))) to (((5))), wherein:

the support unit supports the side surface of the recording medium whose height decreases toward the front end and does not support the front end and/or the rear end of the recording medium.

(((7)))

The image forming apparatus according to any one of (((1))) to (((5))), wherein:

the support unit supports the front end or the rear end of the recording medium and has a height equal to or lower than a height of the front end or the rear end of the recording medium.

(((8)))

The image forming apparatus according to (((7))), wherein:

the support unit supports the front end of the recording medium whose height decreases toward the front end and has a height equal to or lower than a height of the front end of the recording medium.

(((9)))

The image forming apparatus according to (((7))) or (((8))), wherein:

the support unit supports the rear end of the recording medium whose height decreases toward the rear end and has a height equal to or lower than a height of the rear end of the recording medium.

(((10)))

The image forming apparatus according to any one of (((1))) to (((9))), wherein:

the support unit does not make contact with the transfer unit at least during a period in which the transfer unit is transferring an image onto the image formation surface of the recording medium.

(((11)))

The image forming apparatus according to any one of (((1))) to (((10))), wherein:

the support unit supports the recording medium whose height decreases toward the front end and does not make contact with the transfer unit before the transfer unit makes contact with the recording medium.

IMAGE FORMING APPARATUS

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Priority Claims (1)