Patent Application
20090016762
1. Field of the Invention
The present invention relates to an image forming apparatus using an electrophotographic method or an electrostatic recording method, particularly, an image forming apparatus such as a copying machine, printer, facsimile (FAX), and multifunction peripheral including a plurality of these functions.
2. Description of the Related Art
A conventional image forming apparatus such as a copying machine and printer using an electrophotographic method forms a patch image on a photosensitive member, and corrects image forming condition of an image forming process device based on a result of detected density of the patch image.
For example, an apparatus discussed in Japanese Patent Application Laid-Open No. 2005-316064 includes, in order to correct an image forming condition of an image forming process device, an image density sensor of an optical type at a position facing a photosensitive member.
Further, Japanese Patent Application Laid-Open No. 2005-316064 employs a configuration in which a detection window of the image density sensor is closed with a shutter when detection is not performed to prevent scattered toner from contaminating the image density sensor.
However, when the shutter is provided in the image forming apparatus, a new problem arises that the scattered toner adheres to an outer surface of the shutter.
If a large amount of toner adheres to the shutter, when the density of the patch image is detected during a job for continuously forming a plurality of images, the toner may be scattered from the shutter when the shutter is opened and closed, and adhere to a primary image.
In other words, every time the shutter is opened and closed to detect the density of the patch image, the toner scattered from the shutter may generate a fault in an image.
The present invention is directed to an image forming apparatus in which a fault in an image generated by toner adhering to a shutter is suppressed.
An image forming apparatus includes a toner image forming device configured to form a toner image on an image conveying member, a detector configured to optically detect a density of the toner image on the image conveying member, a controller configured to control an image forming condition of the toner image forming device based on an output of the detector, and a shutter configured to open and close an optical window of the detector. The image forming apparatus is operable in a cleaning mode of the shutter in which an opening and closing movement of the shutter is repeatedly executed.
Further features and aspects of the present invention will become apparent from the following detailed description of exemplary embodiments with reference to the attached drawings.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate exemplary embodiments, features, and aspects of the invention and, together with the description, serve to explain the principles of the invention.
Various exemplary embodiments, features, and aspects of the invention will be described in detail below with reference to the drawings.
The image forming apparatus according to the present embodiment is an image forming apparatus using an intermediate transfer belt.
A photosensitive drum 1 as an image bearing member is rotatably about a rotation shaft la provided. Over the photosensitive drum 1, a charging device 2 serving as an electrostatic image forming device and a laser unit 3 are disposed. The charging device 2 is used for uniformly charging a surface of the photosensitive drum 1. The laser unit 3 is used for selectively exposing the surface of the photosensitive drum 1 which has been uniformly charged, according to image signals to form an electrostatic latent image on the surface of the photosensitive drum 1.
A development device 4 is used for visualizing the electrostatic latent image formed on the photosensitive drum 1 with toner. The development device 4 includes four developing units 4Y, 4M, 4C and 4K for each toner of yellow (Y), magenta (M), cyan (C) and black (K). Each of these developing units 4Y, 4M, 4C and 4K is mounted on a rotatable rotary 5.
The rotary 5 rotates to selectively place the desired developing device at a developing position that faces the photosensitive drum 1. Each of the developing units contains two-component developer including toner and carrier.
Below the photosensitive drum 1, an intermediate transfer belt 6 serving as an image conveying member or transfer medium is rotatably suspended by a drive roller 7a, a driven roller 7b, a primary transfer roller 8, and a secondary transfer roller 9.
Bias voltage is applied to a transfer roller 8 (i.e., a transfer device). As a result, the toner images visualized with each of the developing devices 4Y, 4M, 4C and 4K are sequentially transferred at a transfer position T1 to generate a multi-transferred toner image on a surface of the intermediate transfer belt 6.
A recording material P serving as the transfer medium is fed from a feeding cassette 10 to a feed roller 11, a separation roller pair 12, a conveyance roller pair 13, and a registration roller pair 14. The recording material P waiting at the registration roller 14 is sent to a transfer position T2 in synchronization with the toner image on the intermediate transfer belt 6.
The transfer roller 15 is configured to freely contact with or keep away from the intermediate transfer belt 6. When a multi-transfer process is executed on the intermediate transfer belt 6, the transfer roller 15 keeps away from the intermediate transfer belt 6. When a transfer process onto the recording material is executed, the transfer roller 15 contacts the intermediate transfer belt 6. The toner images on the intermediate transfer belt 6 are collectively transferred onto the recording material P at the transfer position T2 owing to an effect of bias voltage applied to the transfer roller 15.
The toner image carried by the recording member P is fixed with heat and pressure generated by the fixing device 16. The recording member P is discharged to a discharge unit by discharge roller pairs 17.
The photosensitive drum 1 is provided with a drum cleaner 18, and the intermediate transfer belt 6 is provided with a transfer cleaner 19. Both of the cleaners employ a blade cleaning method. The drum cleaner 18 cleans off toner that has not been transferred to the transfer belt and remains on the photosensitive member in a primary transfer process. The transfer cleaner 19 is configured to freely contact with and keep away from the intermediate transfer belt 6, and cleans off toner that has not been transferred and remains on the intermediate transfer belt 6.
According to the present embodiment, at a position downstream of a developing position and upstream of the transfer position T1 in a rotational direction of the photosensitive drum 1, a density sensor unit 100 serving as a detector is disposed. The density sensor unit 100 and the photosensitive drum 1 are disposed close to each other.
The density sensor unit 100 is used to detect density of a patch image formed under preset conditions of outputting the images and control conditions of image formation by a controller (central processing unit (CPU)) 300.
More specifically, the controller 300 controls a toner supply amount to the development device 4 based on a density detection result of the patch image detected by the image density sensor 100. Further, the controller 300 adjusts an exposure light amount of the laser unit 3 based on the result of density detection by the image density sensor 100 and controls the output image density.
The image density unit 100 includes a light emitting element 102 and a light receiving element 103 provided within a casing 101. The light emitting element 102 emits light through a window portion 101a that is an optical window of the casing 101, onto the surface of the photosensitive drum 1. The light receiving element 103 in the casing detects light of the patch image reflected on the photosensitive drum 1 through the window portion 101a. The window portion 101a is made from a light transmissive member such as acrylic.
If a large amount of scattered toner adheres to a surface of the window portion 101a of the casing 101, accuracy of density detection of the patch image is deteriorated. However, as will be described below, the present embodiment is provided with a shutter for opening and closing the window portion 104a.
The present embodiment is provided with the shutter 104 as a shielding member between the window portion 101a and the surface of the photosensitive drum 1. The shutter 104 is controlled to open when the patch image comes closer to a portion facing the window portion 101a, and to close when the patch image passes the portion facing the window portion 101a.
Thus, it is possible to prevent contamination of the window caused by the toner adhering to the window portion 101a of the casing 101. The shutter 104 is configured to linearly make an opening and closing movement in a rotational-axis direction of the photosensitive drum 1 along a shutter guide 120 illustrated in
The shutter 104 is provided with an aperture 104a.
The opening and closing movements of the shutter 104 are driven by a solenoid 105 via an arm 106.
An opening and closing system of the shutter 104 is configured as follows. The state illustrated in
When the plunger 108 completely pulls off the arm 106 as illustrated in
After the density of the patch image has been detected, when the solenoid 105 is not excited, the shutter 104 slides back in a direction opposite to the arrow A due to a restoring force of the spring 107. Accordingly, the state of
A shutter controller 200 controls a movement of solenoid 105. As the patch image comes closer to the portion facing the window portion 101a, the shutter controller 200 opens the shutter as illustrated in
The present embodiment is further configured to include a cleaning member 111 on a surface of the shutter 104 facing the casing 101. The cleaning member 111 cleans the window portion 101a along with the opening and closing movements of the shutter 104. Thus, if the toner adheres to the window portion 101a, only with opening and closing movements of the shutter 104, the toner can be cleaned off.
Next, with reference to
A timing chart in
As illustrated in
When a predetermined time has elapsed since the patch image forming signal was input into the controller 300, the shutter controller 200 moves the shutter 104 to open the window portion 101a.
When a predetermined time has elapsed since the shutter 104 was opened, that is, when the density detection of the patch image is completed, the shutter 104 is moved to close the window portion 101a. When the shutter 104 executes a closing movement, a next primary image is already placed at the position facing the window portion 101a.
The closing movement of the shutter 104 may also be executed when a predetermined time has elapsed since the detection of the density of the patch image was completed.
The detection of the density of the patch image as described above, that is, the opening and closing movements of the shutter 104 are repeatedly executed every time the patch image reaches the position facing the window portion 101a.
The shutter controller 200 inserts a mode of cleaning the shutter 104 at a predetermined timing during the continuous job. A timing of insertion of the cleaning mode will be described later. When the cleaning mode is inserted as described above, the continuous job is temporarily suspended.
During the cleaning mode, a motor driving the photosensitive drum 1 is turned off so that the photosensitive drum 1 stops rotation. At this point, a motor driving the development device 4 is also turned off. Further, charging bias and developing bias are also turned off.
In the cleaning mode, the shutter controller 200 executes the continuous opening and closing movements ten times, and finally stops the movement of the shutter 104 with the window portion 101a closed.
When the cleaning mode is completed, that is, when the continuous opening and closing movements of the shutter 104 are completed after the opening and closing movements are repeated ten times, the cleaning mode is cancelled to resume the continuous job.
Next, it is described through what routes scattered toner accumulated on an outer surface of the shutter 104 moves to the photosensitive member due to a shake caused by the opening and closing movements of the shutter 104, with reference to
In
In the present embodiment, the toner having dropped through the route 22 is received and collected by a toner receiver (collecting container) 400 disposed below the image density sensor unit 100.
On the other hand, the toner traveling to the photosensitive drum 1 through the route 23 is a problem. Atoner amount and frequency of traveling of the toner to the photosensitive drum 1 increase as a gap between the image density sensor unit 100 (shutter 104) and the photosensitive drum 1 is made narrower to increase detection accuracy.
The toner amount accumulated on the shutter 104 increases as the toner amount scattered during the opening and closing movements of the shutter 104 increases. Thus, the scattered toner on the primary image is readily visualized.
Therefore, it is desirable that the toner amount accumulated in the shutter 104 should be maintained under a predetermined amount so that the toner scattered during the opening and closing movements of the shutter 104 is not visualized.
For that purpose, in the present embodiment, before the toner amount accumulated on the shutter 104 is increased to an amount enough to affect the primary image, the cleaning mode is executed to reduce or eliminate the toner accumulated on the outer surface of the shutter 104.
Next, image ratios and contamination levels of the shutter 104 are discussed. As illustrated in
Image ratio 10%: Level A (almost no toner contamination)
The toner contamination of the shutter 104 was counted for two cases, that is, where a size of a fault portion in an image caused by the toner scattered from the shutter 104 is more than 0.3 mm, and where a size thereof is 0.3 mm or less.
In the examination of the toner contamination, a number of appearances of the fault in the image when 100 images are continuously formed on A3-size papers, was counted. On the assumption that the density of the patch image is to be detected, the opening and closing movements of the shutter 104 are once executed every time the image of an A3-size paper is formed. Since the shutter 104 executes the closing movement when the toner image is placed at a position facing the image density sensor unit 100, a lump of toner scattered along with the opening and closing movement of the shutter 104 may travel to the toner image.
Image forming speed (rotation speed of the photosensitive drum 1): 300 mm/s
It was found that the toner contamination is not visualized on the image if the toner contamination of the shutter 104 is maintained at the level A or B.
Next,
More specifically, after the toner has been accumulated such that the toner lump is scattered from the shutter 104 (when the number of the movements of the shutter 104 is 0), it was examined how many times the opening and closing movements of the shutter 104 need to be executed so that no image faults are generated when the subsequent primary image is formed.
This examination was executed under conditions that are described as follows. First, [1] hundred black-solid images (A3-size papers) having 100% of the image ratio are continuously formed (the number of opening and closing of the shutter 104 is 0). [2] The opening and closing movements of the shutter 104 are repeated the set number of times.
Then, [3] When hundred white-solid images (A3-size papers) having 0% of the image ratio are continuously formed, the number of the white-solid images to which the toner transferred from the shutter 104 adheres was counted.
As illustrated in
In order to maintain the contamination level of the shutter 104 at the level A or B, it is desirable that the opening and closing movements of the shutter 104 are executed to clean the shutter 104 other than when the density of the patch image is detected.
In the present embodiment, therefore, the shutter controller 200 inserts the opening and closing movements of the shutter 104, that is, the cleaning mode during the job based on the image ratio when the number of times the images are formed, that is, image formation history information, reaches the predetermined number of times (the number of forming the images reaches the predetermined number).
The image formation history refers to data corresponding to the image ratios from one to a plurality of primary images which were formed in the past. In the present embodiment, the image formation history refers to an average value of the image ratios per image obtained when the number of image formations reaches the predetermined number. However, it is not limited thereto, but it may also be a value of a toner consumption amount or a toner supply amount relative to the image ratio.
Further, the cleaning mode of the shutter 104 may be executed based on only the number of times the images are formed as a trigger of an execution timing.
In step S1, the continuous print job is started. The controller 300 counts the number of times the images are formed and stores the counted number in a memory. In step S2, every time the image is formed, the controller 300 determines whether the counted number reaches fifty.
When the number of times of image formations is less than fifty (NO in step S2), the controller 300 continues the image forming movements without inserting the cleaning mode (YES in step S6).
When the number of times of image formations reaches fifty (YES in step S2), the controller 300 calculates the average image ratio per image. In other words, the controller 300 totalizes the image data, and then divides the totalized value by fifty to calculate the image ratio per image formation.
Here, calculation of the image ratio will be described. First, as a route for outputting the image, image information input to an image processing unit that is a part of the controller 300 is converted into a signal and sent to a printer controller that executes image formation with the image signal. An image ratio calculation unit in the controller 300 counts the image signal and stores the counted numbers in the memory. The image ratio calculation unit calculates the image ratio based on the counted image signal.
In other words, the number of the image signals in one image (i.e., an amount of image portion in one image region) is counted to acquire the image ratio. The present embodiment uses the image ratio for one image formation (for one sheet of the recording member). Thus, the image ratio is 100% for a solid image while the image ratio is 0% for no image.
In step S3, the controller 300 determines whether the average value of the image ratios exceeds 70%. If the average value of the image ratios exceeds 70% (YES in step S3), in step S4, the controller 300 enables the shutter controller 200 to execute the cleaning mode. That is, the controller 300 temporarily suspends the continuous print job to execute the cleaning mode.
In step S5, the shutter controller 200 repeats the cleaning mode until the continuous opening and closing movements of the shutter 104 are repeated ten times. Finally, the shutter controller 200 stops the movement of the shutter 104 with the window portion 101a shielded.
On the other hand, if the average value of the image ratios is 70% or less (NO in step S3), the controller 300 continues the print job without inserting the cleaning mode during the job (YES in step S6). When the cleaning mode is not inserted, as long as the image formation is continuously performed, the average value of the image ratios in the last fifty image formations is being updated.
When the cleaning mode is completed, the controller 300 clears the number of times the images are formed and the image ratios data in the last fifty image formations which are stored in the memory. When the job is continued, the controller 300 starts counting the number of image formations and the image ratios again, and sequentially stores the counted number in the memory.
As long as the job continues (YES in step S6), the above-described sequence is repeated. Finally, the job is completed (NO in step S6, and in step S7).
As described above, in the present embodiment, a timing of executing the cleaning mode is determined every time the number of image formations on A4-size papers reaches fifty. However, the timing of executing the cleaning mode may also be determined every time the number of image formations on A3-size papers reaches twenty-five. Thus, it is desirable that the number of image formations that is a reference for executing the cleaning mode is changed depending on a size of the recording member.
Further, in the present embodiment, when the number of image formations reaches fifty during the job, it is determined whether the cleaning mode is executed. However, the average value of the image ratios may also be calculated when the number of times reaches a predetermined number that is less than fifty. More specifically, the average value may be calculated when the number of image formations reaches thirty five, and it is determined whether the cleaning mode may be executed.
In the present embodiment, if the acquired image ratio is more than 70%, the number of the opening and closing movements of the shutter 104 in the cleaning mode is set to ten. However, it is desirable that the shutter controller 200 changes the number of the opening and closing movements of the shutter 104 in the cleaning mode depending on the image ratio. More specifically, as illustrated in
A second exemplary embodiment of the present invention has a similar configuration to the first exemplary embodiment except for the following descriptions. Accordingly, the same reference numerals are assigned to similar components and the detailed descriptions thereof will be omitted.
In the second exemplary embodiment, the timing of execution of the cleaning mode is determined depending on the contamination level (light transmissivity) on a detection surface of the image density sensor unit 100.
First, contamination of the image density sensor will be described.
Depending on usage history of the image formation, a relationship between a toner-contamination amount adhering to the image density sensor unit 100 and a toner cleaning amount removed by the cleaning member 111 (refer to
Accordingly, the present embodiment employs light transmissivity of the window 101a as an index corresponding to the toner contamination of the window portion 101a that is related to the image ratio. The light transmissivity is obtained by comparing reference light to reflected light from the photosensitive drum 1 onto which the toner is not transferred. The reference light refers to a light amount of the light emitting element 102 in the image density sensor unit 100. The reflected light from the surface of the photosensitive member is light reflected from the photosensitive drum 1 when the light is emitted from the light emitting element 102 in the image density sensor unit 100 to the photosensitive drum 1.
Even though the window portion 101a is contaminated with the toner, the light amount of the light emitting element 102 (light source) can be changed. Accordingly, the density of the patch image on the photosensitive drum 1 can be detected without any problems.
When the images having the high image ratios are continuously formed, the light transmissivity is more lowered than expected (a solid line 52 in
In the present embodiment, the detection of the light transmissivity is performed in a non-image region where the patch image is not formed at timing between a preceding primary image and a subsequent primary image (a period 63 in
In the present embodiment, the controller 300 determines the toner contamination level of the shutter 104 based on history (ratio of change) of the light transmissivity of the window portion 101a. That is, when the light transmissivity measured this time is largely reduced compared to a previous time, the controller 300 determines that the job for forming the images having the higher image ratios has been executed.
A flow for setting the threshold value to the ratio of change of the contamination level (light transmissivity) of the window portion 101a, inserting the cleaning mode when the ratio of change reaches the threshold value, and forcibly opening and closing the shutter 104 will be described with reference to
In step S11, continuous print job is started. The controller 300 counts the number of times the images are formed and stores the counted number in the memory. In step S12, every time the image is formed, the controller 300 determines whether the counted number reaches fifty. When the number of image formations is less than fifty (NO in step S12), the controller 300 continues the image forming movements without inserting the cleaning mode (YES in step S16).
When the number of image formations reaches fifty (YES in step S12), the controller 300 calculates the ratio of change of the light transmissivity for fifty image formations. That is, the controller 300 detects the light transmissivity at the time of first image formation when starting to count the number and the light transmissivity detected when the number of image formations reaches fifty in order to calculate reduction of the light transmissivity. The reduction can be calculated by a following expression.
(transmissivity for the fiftieth time/transmissivity for the first time)×100(%)
In step S13, the controller 300 determines whether the reduction exceeds 20%. When the reduction exceeds 20% (YES in step S13), in step S14, the controller 300 executes the cleaning mode. That is, the controller 300 suspends the continuous print job to execute the cleaning mode.
In step S15, the shutter controller 200 repeats the cleaning mode until the shutter 104 repeats continuous opening and closing movements ten times. Finally, the shutter controller 200 stops the movements of the shutter 104 with the window portion 101a shielded.
When the reduction is 20% or less (NO in step S13), the controller 300 continues the print job without inserting the cleaning mode (YES in step S16).
When the cleaning mode is completed, the controller 300 clears counted values of the number of image formations. When the job is continued (YES in step S16), the controller 300 starts counting the number of image formations and repeats a sequence described above. At last, the controller 300 completes the job (NO in step S16, and in step S17).
In the present embodiment, when the reduction is larger than 20%, the number of opening and closing movements of the shutter 104 in the cleaning mode is set to ten. However, the shutter controller 200 may change the number of opening and closing movements of the shutter 104 depending on a value of the reduction. More specifically, the number of movements of the shutter 104 is increased as the reduction is increased.
According to the first and second exemplary embodiments, the cleaning mode is automatically inserted and executed during the image forming job. Further, the cleaning mode may also be executed when a post-rotation is performed during a post process in the image forming apparatus after completing the image forming job. Furthermore, the cleaning mode may also be executed when a pre-rotation is performed during a pre-process in the image forming apparatus in a period after a starting signal is input and before the image forming movement is started.
According to the first and second exemplary embodiments, the image density sensor unit is disposed at a position facing the photosensitive drum 1 to detect the density of the patch image formed on the photosensitive drum 1, however, the following configuration may also be employed. The image density sensor unit may be disposed at a position facing the intermediate transfer member to detect the density of the patch image transferred onto the intermediate transfer member from the photosensitive drum 1.
According to the first and second exemplary embodiments, the controller 300 and the shutter controller 200 are configured to issue instructions and directions for executing the cleaning mode. However, the following configuration may also be employed. That is, when the image forming apparatus is used as a printer connected to a host computer through a local area network (LAN) cable, the cleaning mode may be executed based on an instruction of a user from the host computer.
In this case, an interface unit of the image forming apparatus receives a start signal of the cleaning mode from the host computer through the LAN cable. Based on the start signal, the shutter controller 200 drives the solenoid 105. As a result, the shutter 104 repeats the opening and closing movements a plurality of times to perform the cleaning of the shutter 104.
In the first and second exemplary embodiments, the cleaning mode of the image density sensor unit 100 and the shutter 104 is described. However, the present invention can also be applied to the following configuration.
As illustrated in
In this case, in order to prevent the toner from entering within the shield of the corona charging device 500, the shutter 104 for opening and closing the aperture is formed in the shield similar to the above exemplary embodiments. In order to perform the cleaning on the shutter 104, the cleaning mode is executed similar to the above exemplary embodiments.
Thus, in the image forming apparatus that uses the corona charging device 500 as illustrated in
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all modifications, equivalent structures, and functions.
This application claims priority from Japanese Patent Application No. 2007-181111 filed Jul. 10, 2007, which is hereby incorporated by reference herein in its entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2007-181111 | Jul 2007 | JP | national |
