1. Field of the Invention
The present invention relates to an image forming apparatus which includes a developing device including a toner bearing member and a toner supply member configured to supply toner to the toner bearing member, the image forming apparatus further including a detection unit configured to detect a capacitance between the toner bearing member and the toner supply member.
2. Description of the Related Art
There are methods for detecting the amount of toner remaining in a developing device used in an image forming apparatus such as an electrophotographic apparatus. Among those is a capacitance detection method which includes detecting a capacitance between two electrodes arranged inside the developing device to obtain information about the amount of the remaining developer.
In particular, when using a developing device that includes a developing roller serving as a toner bearing member and a supply roller including a foam layer serving as a toner supply member, a detection method discussed in Japanese Patent Application Laid-Open No. 2009-265282 may be used. The detection method includes detecting a capacitance between a core of the developing roller and a core of the supply roller to obtain information about the amount of remaining toner.
Such a method can measure the amount of remaining toner by detecting the capacitance between the cores because the amount of the remaining toner in the developing device and the capacitance are correlated with each other. To accurately detect the amount of the remaining toner, the method discussed in Japanese Patent Application Laid-Open No. 2009-265282 includes rotating the supply roller at predetermined speed for a predetermined time before the detection of the capacitance, thereby stabilizing the amount of the toner in the foam layer.
According to the method discussed in Japanese Patent Application Laid-Open No. 2009-265282, the supply roller is to be rotated for a predetermined time to detect the remaining amount. This imposes an extra load on the toner as much as the supply roller is driven, which can promote toner degradation.
The present invention is directed to an image forming apparatus that detects an amount of remaining toner based on a capacitance between an electrode member of a toner bearing member and an electrode member of a toner supply member, and that can accurately detect the amount of the remaining toner and reduce toner degradation.
According to an aspect of the present invention, an image forming apparatus image includes an image bearing member configured to support an electrostatic latent image, a developing device including a developer bearing member and a supply member, wherein the developer bearing member includes a first electrode member and is configured to support a developer to develop the electrostatic latent image, and wherein the supply member includes a second electrode member and is configured to supply the developer to the developer bearing member at a nip portion between the supply member and the developer bearing member, a holding unit configured to hold and change the developing device to a first posture and to a second posture in which the developer deposited on the nip portion in the first posture falls off, and a detection device configured to detect an amount of a remaining developer in the developing device based on a first capacitance C1 between the first electrode member and the second electrode member in the first posture and a second capacitance C2 between the first electrode member and the second electrode member in the second posture.
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 following exemplary embodiments describe the present invention by way of examples . The scope of an exemplary embodiment is not limited to the dimensions, materials, shapes, or relative arrangement of the components described below unless otherwise specified.
A first exemplary embodiment will be described.
The image forming apparatus includes a rotating drum type electrophotographic photosensitive member (hereinafter, referred to as a drum) 1 as an image bearing member which bears an electrostatic latent image on its surface. The image forming apparatus further includes a charging unit 2, an image exposure unit 3, a developing device 5, a transfer unit 6, a drum cleaning unit 7, and a fixing unit 8 as process units that act on the drum 1.
The drum 1 rotationally drives about a drum axis in a clockwise direction indicated by the arrow R1 at predetermined speed. The charging unit 2 uniformly charges the surface of the drum 1 to a predetermined polarity (in the present exemplary embodiment, negative polarity) and potential. In the present exemplary embodiment, a contact charging roller is used as the charging unit 2. The image exposure unit 3 forms an electrostatic latent image on the surface of the drum 1 via a mirror 4. In the present exemplary embodiment, a laser scanner unit is used as the image exposure unit 3. The developing device 5 is a unit that visualizes the electrostatic latent image formed on the drum surface into a developer image (toner image).
In the present exemplary embodiment, the developing device 5 is a reversal developing device of contact developing type which uses negatively chargeable nonmagnetic toner as a developer T. The transfer unit 6 transfers the toner image visualized on the drum surface to a recording material P serving as a transfer material. A transfer roller is used as the transfer unit 6. The drum cleaning unit 7 removes transfer residual toner from the surface of the drum 1 after transfer. A cleaning blade is used as the drum cleaning unit 7. The toner removed from the drum surface is stored in a cleaner container 71. The recording material P with the transferred toner image is guided into the fixing unit 8, and heated and pressed by a fixing nip portion. The toner image is thereby fixed to the recording material P.
Completing an image forming job on one sheet or a continuous plurality of sheets, the controller unit 100 puts the image forming apparatus into a standby state and waits for the input of a next image formation start signal. Specifically, the controller unit 100 stops driving the drum 1, the laser scanner unit 3, and the transfer unit 6.
The developing device 5 will be described.
The developing device 5 includes a toner container 13, a developing roller 9, and a supply roller 10. The toner container 13 contains toner T. The developing roller 9 serves as a toner bearing member for developing an electrostatic image formed on the drum 1. The supply roller 10 serves as a toner supply member which makes contact with the developing roller 9 to supply the toner T. The developing device 5 further includes a regulation blade 11 and a leak prevention seal 12. The regulation blade 11 serves as a layer thickness regulation member which regulates the thickness of the toner layer on the developing roller 9. The leak prevention seal 12 prevents leakage of the toner T from a gap between the developing roller 9 and the toner container 13.
The toner container 13 is an oblong container whose longitudinal direction is in the axial direction of the drum 1. The toner container 13 has an opening in its lower portion. The opening is opposed to the drum 1 along the longitudinal direction of the toner container 13. The developing roller 9 is located in the opening and arranged in parallel to the longitudinal direction of the toner container 13. The developing roller 9 is rotatably supported by the toner container 13 via bearing members (not illustrated) that are respectively attached to both longitudinal ends of the toner container 13. The supply roller 10 is arranged inside the toner container 13 in parallel with the developing roller 9, on the other side of the developing roller 9 from where the developing roller 9 is opposed to the drum 1. The supply roller 10 is rotatably supported by the toner container 13 via bearing members (not illustrated) that are respectively attached to both longitudinal ends of the toner container 13.
In the present exemplary embedment, the developing roller 9 has a diameter of φ 13. The developing roller 9 includes a φ 8 conductive core (first electrode member) 9a which is covered with a base layer of silicon rubber and further coated with acrylic urethane rubber. The developing roller 9 has a volume resistance of 104 to 1012 Ω·cm.
The supply roller 10 is a φ 15 urethane sponge roller, including a φ 6 conductive core (second electrode member) 10a covered with a urethane sponge layer 10b serving as a foam layer of open-cell foam. The urethane sponge layer 10b has a volume resistance of around 104 to 1012 Ω·cm. The distance (center distance) between the core 9a of the developing roller 9 and the core 10a of the supply roller 10 is 13 mm. The urethane sponge layer 10b of the supply roller 10 intrudes into the surface of the developing roller 9 by 1.0 mm.
The regulation blade 11 is a flexible member made of phosphor bronze or urethane rubber. The extremity of the regulation blade 11 slides over the developing roller 9 to form the toner T applied to the developing roller 9 into a thin coating layer. The regulation blade 11 is arranged on the toner container 13 with its base fixed to the upper edge of the opening.
The leak prevention seal 12 is a flexible member whose extremity is in contact with the developing roller 9 to cover a gap between a lower portion of the developing roller 9 and the toner container 13, thereby preventing leakage of the toner T. The leak prevention seal 12 is arranged on the toner container 13 with its base fixed to the lower edge of the opening.
In the present exemplary embodiment, the developing device 5 in the first posture is opposed to the drum 1 in an upright position with the top side of the toner container 13 upward and the bottom side downward. The developing roller 9 of such a developing device 5 is in contact with the drum 1. The developing roller 9 in contact with the drum 1 develops an electrostatic latent image formed on the drum 1. In other words, the developing device 5 uses a contact developing method.
When performing image formation, driving force and a developing bias are input to the developing device 5 in the first posture from a driving unit (not illustrated) and a power supply unit on the main body side of the image formation apparatus. The developing roller 9 rotationally drives at predetermined speed in a counterclockwise direction indicated by the arrow R2 in
The rotating supply roller 10 applies the toner T to the periphery of the rotating developing roller 9. The regulation blade 11 forms the applied toner T into a thin coating layer. The thin layer of the toner T is conveyed to a development position by the subsequent rotation of the developing roller 9, and applied to the surface of the drum 1. A developing bias power supply unit applies a predetermined developing bias (a direct-current (DC) voltage in the present exemplary embodiment) to the developing roller 9. As a result, the thin layer of the toner T on the periphery of the phase roller 9 is selectively transferred to the drum surface according to the electrostatic latent image on the drum surface. The electrostatic latent image is thereby developed as a toner image. The toner T not provided for the development of the electrostatic latent image is conveyed back into the toner container 13 by the subsequent rotation of the developing roller 9. The supply roller 10 removes the toner T from the surface of the developing roller 9 and applies the toner T again to the surface of the developing roller 9. Such an operation is repeated to develop the electrostatic latent image on the drum surface.
As described above, the developing device 5 in the first posture is in an upright position. By gravity, the toner T in the toner container 13 lies vertically below in the lower portion of the toner container 13(container bottom side) where the supply roller 10 is arranged. The toner T stored in the toner container 13 has a toner surface (developer surface) Ta. In the first posture, the toner T is deposited up to above the contact portion (nip portion) between the developing roller 9 and the supply roller 10 (the area X in the diagram). In such a posture, the developing device 5 can supply the toner T to the supply roller 10. As a result, the toner T can be applied to the developing roller 9.
A method for detecting the amount of remaining toner in the developing unit will be described. The remaining amount has conventionally been detected by determining a capacitance between the supply roller and the developing roller in one posture. To detect the amount of the remaining toner with high accuracy, the supply roller has been rotated at predetermined speed for a predetermined time to stabilize the amount of toner in the foam layer before the detection of the capacitance. Since the supply roller is to be rotated for a predetermined time to detect the remaining amount, the toner undergoes an extra load as much as the supply roller is driven, which can promote toner degradation.
In view of the foregoing, in the present exemplary embodiment, the amount of the remaining toner T in the developing device 5 is detected based on a difference between a capacitance C1 in the developable first posture and a capacitance C2 in the second posture where the toner T deposited on the contact portion between the developing roller 9 and the supply roller 10 in the first posture is let fallen off. The result of detection C1 depends on both the amount of the toner T in the supply roller 10 and the amount of the toner T in the area X. On the contrary, the result of detection C2 depends only on the amount of the toner T in the supply roller 10. A difference between C1 and C2 can thus be determined to eliminate the effect of the amount of the toner T in the supply roller 10 and detect the amount of the toner T in the area X.
Next, the method for detecting the remaining amount will be described. The amount of the toner T remaining in the developing device 5 is detected by a remaining amount detection device 100a. As illustrated in
Next, the relationship between the rotation time of the supply roller 10 and the capacitance will be described. As illustrated in
Next, the correlation between the amount of the toner T in the area X and the capacitance in the first posture will be described. While repeating a print job, the toner T in the area X is agitated to maintain a constant density. Changes of the capacitance and the amount of the toner T in the toner container 13 were measured in the first posture when the toner T in the area X maintained a constant density. To prevent a change in the amount of the toner T in the supply roller 10, the supply roller 10 was not rotated during the measurement of the capacitance.
Next, the method for detecting the remaining amount will be described in detail with reference to
While in the present exemplary embodiment, the amount of the remaining toner T is indicated by executing a warning display of the “no toner”, the amount of the remaining toner T may be displayed in terms of the remaining number of sheets capable of image formation. A display for prompting the user to replace the development device 5 may be made.
In the present exemplary embodiment, the amount of the remaining toner T is detected based on a difference between the capacitances C1 and C2. However, the amount of the remaining toner T may be detected based on a ratio between the capacitances C1 and C2. For example, the remaining amount detection device 100a may determine that there is “no toner” and may execute warning display if C2/C1 exceeds a threshold. The remaining amount detection device 100a can thus detect the amount of the remaining toner T based on a comparison between the capacitances C1 and C2.
A second exemplary embodiment will be described.
The image forming apparatus according to the second exemplary embodiment includes the plurality of developing devices 5 serving as developing units. More specifically, the image forming apparatus includes first to fourth four developing devices 5. A rotary 14 serving as a holding unit holds the plurality of developing devices 5. The rotary 14 is rotatably supported and can rotate and move a desired developing device 5 (for example, the developing device 5a) to a development position A where the developing device 5 is opposed to and makes contact with the photosensitive drum 1.
The image forming apparatus further includes a transfer belt 61 as an intermediate transfer member. The transfer belt 61 is rotatably arranged being suspended by a plurality of rollers. The photosensitive drum 1 and the transfer belt 61 are pressed against and make contact with each other in a primary transfer position B, where a primary transfer roller 62 is arranged to sandwich the transfer belt 61 between the photosensitive drum 1 and the primary transfer roller 62. A toner image formed in the development position A is transferred to the transfer belt 61 in the primary transfer position B. A recording material P and the transfer belt 61 are pressed against and make contact with each other in a secondary transfer position C, where a secondary transfer counter roller 63 and a secondary roller 64 are arranged. The secondary transfer counter roller 63 is arranged to suspend the transfer belt 61. The secondary transfer roller 64 is configured to be able to come into contact with and separate from the transfer belt 61. A transfer cleaning device 65 is arranged downstream of the secondary transfer position C in the moving direction of the transfer belt 61. The transfer cleaning device 65 is arranged in contact with the transfer belt 61 so that a blade attached to the transfer cleaning apparatus 65 can scrape toner off the transfer belt 61.
Next, an operation for forming a four-color full color image will be described. The photosensitive drum 1 rotationally drives in the direction of the arrow R4 at predetermined speed. The charging unit 2 uniformly charges the drum surface to a predetermined potential. The image exposure unit 3 and a reflection mirror 4 form an electrostatic latent image on the drum surface according to an image signal of each color. A developing device 5 develops the formed electrostatic latent image in the development position A to form a toner image.
The developing device 5 to be located in the development position A is determined according to the color-specific image signals. The rotary 14 is rotated in the direction of the arrow R6 in advance to locate a developing device 5 of desired color in the development position A. Toner images are developed in fixed color order. In the present exemplary embodiment, toner images are formed in the order of yellow, magenta cyan, and black. The toner image formed on the drum 1 is transferred to the transfer belt 61 in the primary transfer position B. Formed toner images are successively superposed on previously transferred ones to form a full color toner image on the intermediate transfer belt 61. The secondary transfer roller 64 and the transfer cleaning device 65 are separated from the transfer belt 61 until the formation of a full color toner image, and are brought into contact with the transfer belt 61 after the formation. A recording material P is conveyed in time with the timing at which the formed full color toner image reaches the secondary transfer position C. The secondary transfer roller 64 and the secondary transfer counter roller 63 sandwich the recording material P and the transfer belt 61 together to transfer the full color toner image to the recording material P. The recording material P with the transferred full color toner image is conveyed to the fixing unit 8. The fixing unit 8 applies heat and pressure to the full color toner image on the recording material P, thereby fixing the full color toner image to the recording material P as a final image.
Next, a method for detecting the amount of remaining toner according to the present exemplary embodiment will be described with reference to
Next, a method for detecting the amount of remaining toner during an image forming operation will be described with reference to the flowchart of
In the present exemplary embodiment, the amounts of the remaining toners are indicated by performing warning display of a “no toner” . However, the amounts of the remaining toners may be displayed in terms of the remaining number of sheets capable of image formation. A display for prompting the user to replace the developing device(s) 5 may be made.
In the present exemplary embodiment, the amounts of the remaining toners are detected after development. However, the amounts of the remaining toners may be detected before development.
In the present exemplary embodiment, the amount of the remaining toner is detected based on difference between the capacitance C1, and the capacitance C2. However, the amount of the remaining toner may be detected based on ratio between the capacitance C and the capacitance C2. For example, the remaining amount detection device 100a may determine that there is “no toner” and may perform warning display if C2/C1 exceeds a threshold. The remaining amount detection device 100a can thus detect the amount of the remaining toner based on a comparison between the capacitance C1 and the capacitance C2.
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. 2011-280096 filed Dec. 21, 2011, which is hereby incorporated by reference herein in its entirety.
Number | Date | Country | Kind |
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2011-280096 | Dec 2011 | JP | national |