Patent Grant
10635032
The present invention relates to an image heating apparatus such as a fixing unit mounted on an image forming apparatus such as a copying machine or a printer which uses an electrophotographic system or an electrostatic recording system or a gloss providing apparatus that heats a fixed toner image on a recording material again to improve a gloss level of the toner image. The present invention also relates to an image forming apparatus including the image heating apparatus.
A film-heating-type apparatus which is excellent in saving energy and can start quickly is known as a fixing apparatus mounted on a conventional image forming apparatus such as a laser printer which uses an electrophotographic system. A technology of controlling a fixing temperature of a fixing unit according to a toner laid-on level calculated from image data to further save energy is known. Japanese Patent Application Publication No. 2016-4231 discloses a method of performing an image thinning process on input image data, determining a largest toner amount of dots in a page (hereinafter referred to as a laid-on level), and increasing a fixing temperature of a fixing unit when fixing an image having a large laid-on level as compared to when fixing an image having a small laid-on level. Moreover, Japanese Patent Application Publication No. 2008-268784 discloses a method of calculating a print ratio in a plurality of regions and performing appropriate temperature control according to the calculation result.
However, the configuration disclosed in the related art is not always accurately applied to a control temperature necessary for fixing. For example, when solid black images of a certain shape are printed, the necessary control temperature is different depending on a method of connecting the images. However, there are cases in which a difference in fixing performance resulting from the size of connecting the images is not expressed appropriately. In the configuration disclosed in Japanese Patent Application Publication No. 2016-4231, the same fixing temperature control is performed if the largest toner laid-on levels are the same. Therefore, it is not possible to cope with a case in which the toner laid-on level is constant and an image shapes are different. In the configuration disclosed in Japanese Patent Application Publication No. 2008-268784, the same fixing temperature control is performed if the print ratios in respective regions are the same. Therefore, it is not possible to cope with a case in which a printing area is constant and a method of connecting images. Therefore, if a control temperature is set so that an image having a shape or an arrangement with the worst fixing performance is fixed sufficiently, the set control temperature increases and the power consumption increases excessively for images having the other shapes or arrangements. Therefore, since a high control temperature is set for an image although the image can be fixed using a low control temperature, energy is consumed unnecessarily.
An object of the present invention is to provide an image forming apparatus which provides satisfactory fixing performance regardless of an image pattern and suppresses unnecessary power consumption to provide excellent energy saving properties.
In order to attain the object, an image forming apparatus of the present invention includes:
an image heating portion including a heater including a substrate and a heat generating element provided on the substrate, the image heating portion heating an image formed on a recording material on the basis of image data using the heat of the heater;
a temperature detection portion that detects a temperature of a heating region of the recording material heated by the heater;
an energization control portion that controls electric power to be supplied to the heat generating element;
an image conversion portion that converts the image data to conversion data including a plurality of regions by converting a predetermined number of picture elements which is a portion of the image data as one of the plurality of regions; and
a continuity acquiring portion that analyzes a value related to a print ratio in each of the regions of the conversion data and acquires a value related to connection indicating how many continuous regions in which the value related to the print ratio exceeds a threshold are adjacent to each other; and
wherein the energization control portion controls energization of the heat generating element on the basis of the temperature detected by the temperature detection portion and a control target temperature calculated from the value related to the connection.
According to the present invention, it is possible to provide an image forming apparatus which provides satisfactory fixing performance regardless of an image pattern and suppresses unnecessary power consumption to provide excellent energy saving properties.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
Hereinafter, a description will be given, with reference to the drawings, of embodiments (examples) of the present invention. However, the sizes, materials, shapes, their relative arrangements, or the like of constituents described in the embodiments may be appropriately changed according to the configurations, various conditions, or the like of apparatuses to which the invention is applied. Therefore, the sizes, materials, shapes, their relative arrangements, or the like of the constituents described in the embodiments do not intend to limit the scope of the invention to the following embodiments.
An image forming apparatus 100 illustrated in
The surface of the photosensitive drum 1 is uniformly charged to a predetermined polarity and a predetermined potential by a charging roller 2. A laser beam from a laser scanner 3 is radiated to the photosensitive drum 1 after the charging whereby an electrostatic latent image is formed on the surface of the photosensitive drum 1. The laser scanner 3 performs scanning exposure with ON/OFF control according to image information to remove charges in an exposed portion to form an electrostatic latent image on the surface of the photosensitive drum 1. The electrostatic latent image is developed and visualized by a developing apparatus 4. The electrostatic latent image is developed as a toner image with toner attached thereto with the aid of a developing roller 4a. The toner is an approximately spherical particle having a grain size of 4 μm to 10 μm containing a binder resin, a wax as a release agent, a coloring material, and the like. A plurality of layers of toner particles is stacked on a solid black printing portion.
A toner image on the photosensitive drum 1 is transferred to a surface of a recording material P. The recording material P is accommodated in a sheet feeding tray 101. The recording material P is fed one by one by a sheet feeding roller 102 and is supplied to a transfer nip portion Nt between the photosensitive drum 1 and a transfer roller 5 by a transport roller 103 or the like. In this case, a leading end of the recording material P is detected by a top sensor 104, and a timing at which the leading end of the recording material P arrives at the transfer nip portion Nt is determined on the basis of the position of the top sensor 104, the position of the transfer nip portion Nt, and a transport speed of the recording material P. The toner image on the photosensitive drum 1 is transferred to the recording material P which has been fed and transported at a predetermined timing as described above when a transfer bias is applied to the transfer roller 5.
The recording material P having the toner image transferred thereto is transported to a heating and fixing apparatus 6 as an image heating portion and is heated and pressurized while being pinched and transported at a fixing nip portion between a heating member 10 and a pressure roller 20 of the heating and fixing apparatus 6 whereby the toner image is fixed to the surface of the recording material P. After that, the recording material P having the toner image fixed thereto is discharged to a sheet discharge tray 107 formed on an upper surface of the image forming apparatus 100 by a sheet discharge roller 106. In the meantime, a sheet discharge sensor 105 detects the timings at which the leading end and the trailing end of the recording material P pass through the sheet discharge sensor 105 to monitor whether a jam or the like has occurred.
On the other hand, the toner which remains on the photosensitive drum 1 without being transferred to the recording material P after the toner image was transferred is removed by a cleaning blade 7a of a cleaning apparatus 7 and is provided for subsequent image forming operations.
By repeatedly performing the above-described operations, images can be formed sequentially. The image forming apparatus of the present embodiment is an example of an apparatus of which the resolution is 600 dpi, the printing speed is 30 pages per minute (LTR vertical feed: process speed of approximately 168 mm/s), and the lifespan is 100,000 pages.
A printer control device 304 according to the present embodiment will be described with reference to
The on/off timing information of the laser scanner 3 is transmitted from the controller portion 301 to an application specific integrated circuit (ASIC) 314. The ASIC 314 controls a portion (such as the laser scanner 3) of the image forming portion that the image forming control portion 340 controls.
On the other hand, the information such as a print mode and the image size is transmitted to a CPU (central processing unit) 311. The CPU 311 controls the temperature of the heating and fixing apparatus 6 with the aid of a fixing control portion 320, controls an operation interval of the sheet feeding roller 102 with the aid of a feeding and transport control portion 330, and controls the process speed and developing, charging, and transferring operations with the aid of an image forming control portion 340. In this control operations, the CPU 311 stores information in a RAM 313, uses programs stored in the RAM 313 or a ROM 312, and refers to the information stored in the RAM 313 or the ROM 312 as necessary.
Furthermore, the controller portion 301 transmits a print command, a cancel instruction, and the like to the engine control portion 302 according to an instruction that a user has issued on a host computer and controls an operation of starting and stopping a print operation.
The film-heating-type heating and fixing apparatus 6 according to the present embodiment will be described with reference to
The heating and fixing apparatus 6 configured in this manner causes the recording material P having the toner image t formed thereon to be pinched and transported at a pressure nip portion (the fixing nip portion) formed by the heating heater 11 and the pressure roller 20 with the aid of the fixing film 13. In this way, the toner image t is fixed to the recording material P.
In
The heating heater 11 has a resistor heat generating layer 112 on a substrate 113. The resistor heat generating layer 112 is covered with an overcoat glass 111 to improve insulation and abrasion resistance properties of the resistor heat generating layer 112, and the overcoat glass 111 is configured to make contact with an inner circumferential surface of the fixing film 13. A small amount of a lubricating agent such as a heat-resistant grease is applied to the surface of the heating heater 11. In this way, the fixing film 13 can rotate smoothly. The substrate 113 of the heating heater 11 of the present embodiment is formed of alumina. The substrate 113 has a width of 6.0 mm, a length of 260.0 mm, and a thickness of 1.00 mm, and the coefficient of thermal expansion thereof is 7.6×10−6/° C. The resistor heat generating layer 112 of the present embodiment is formed of a silver-palladium alloy, a total resistance thereof is 20Ω, and a temperature dependence of resistivity is 700 ppm/° C.
The fixing film 13 is a composite-layer film. That is, the fixing film 13 has a substrate obtained by kneading a thin metallic element tube of SUS or the like or a heat-resistant resin of polyimide or the like with a heat conduction filler of graphite or the like and forming a resulting member into a cylindrical form. The surface of the substrate is coated or tube-covered directly with a releasing layer of PFA, PTFE, FEP, or the like or with a primer layer disposed therebetween. The fixing film 13 used in the present embodiment is a polyimide substrate coated with PFA. A total film thickness is 70 μm and an outer circumferential length is 57 mm.
The pressure roller 20 illustrated in
The pressure roller 20 is pressed with a force of 15 Kg·f by a pressure unit (not illustrated) from both ends in a longitudinal direction so that a nip portion necessary for heating and fixing can be formed. The pressure roller 20 is rotated and driven in the direction (the counter-clockwise direction) indicated by an arrow in
The heater holder 12 holds the heating heater 11 and is formed of a liquid crystal polymer, a phenol resin, PPS, PEEK, or the like. The fixing film 13 is loosely fitted to the heater holder 12 so as to freely rotate. The heater holder 12 used in the present embodiment is formed of a liquid crystal polymer having a heat resistance of 260° C. and the coefficient of thermal expansion of 6.4×10−5/° C.
The fixing control portion 320 as an energization control portion has a temperature control program and controls the temperature of the heating heater 11 to be a predetermined control temperature (a control target temperature) on the basis of the detection temperature detected by the thermistor 14 as a temperature detection element of a temperature detection portion. PID control including a proportional term, an integral term, and a differential term is preferably used as a control method. A heater energization period within a cycle is determined by the PID control, and a heater energization period control circuit (not illustrated) is driven to determine a heater output power. In the present embodiment, the heater output power is updated at the interval of the control cycle of 100 msec.
The control temperature is set on the basis of the information from the image processing portion 303 to be described later. The fixing control portion 320 may correct and set the control temperature by various corrections performed conventionally on the basis of the degree of warming of the fixing apparatus, the environmental temperature and humidity, a print mode, a recording material type, or the like in addition to the information from the image processing portion 303 to be described later in the present embodiment.
In the image forming apparatus of the present embodiment, the other image processing portions 402 perform processing with a resolution of 600 dpi. The calculation processing procedure of the image analysis portion 401 of the present embodiment is performed on the image data obtained when the processing of the other image processing portions 402 ends. However, an image processing procedure is not limited thereto and may be selected appropriately.
The respective steps of the flowchart of the temperature required for fixing calculation method illustrated in
An original image (600 dpi) is divided into meshes M (regions) made up of a plurality of pixels (a plurality of picture elements) and is converted to an mesh image in which an average print ratio of each mesh M (that is, an average value of the ratios that respective pixels included in one mesh M include dots (dots on which toner is laid) serving as image portions) is calculated. Data in which the mesh images are summarized in the entire image corresponds to conversion data of the present invention. Although the size of one side of the mesh M is preferably set to approximately 0.25 mm (8 pixels) to 5 mm (120 pixels), the size is set to 24 pixels by 24 pixels in the present embodiment. The size of one mesh in the present embodiment is approximately 1 mm by 1 mm. Although the necessary control temperature is set according to the length of connection of meshes M in the present embodiment, if the mesh M is too small, it becomes hypersensitive to a very small space between pieces of image data. Moreover, the amount of data to be handled becomes too large. If the mesh M is too large, the detailed data in the mesh M disappears when the original image is converted into a mesh image and image patterns that are to be handled as discrete arrangements may be regarded as a continuous pattern. Therefore, the size of one mesh is set appropriately by taking balance with these factors into consideration.
An original image in which solid black data as illustrated in
In the present embodiment, although the average print ratio of respective pixels is calculated as the mesh data of each mesh M, the mesh data is not limited thereto, and a median value may be used, for example. The most frequent value or the other representative values may be used.
The average print ratio of each mesh M(m,n) is defined as R(m,n). As illustrated in
The image analysis portion 401 is a continuity acquiring portion and calculates the connection information (the sizes of connection in vertical and horizontal directions, that is, the number of continuously adjacent predetermined meshes) of predetermined meshes M having a print ratio R(m,n) of a threshold Th or more from a mesh image. In the present embodiment, a vertical connection length and a horizontal connection length are calculated for meshes M having a high print ratio of 50% or more of a threshold from the mesh image illustrated in
Each of the two-valued meshes M is defined as E(m,n).
E(m,n)=1 (if R(m,n)≥Th)
0(if R(m,n)<Th) Equation 1
When a horizontal connection length Lh(m,n) is calculated, first, the number of continuous meshes M of which the print ratio exceeds the threshold is counted in the leftward direction from the mesh M of which the print ratio is equal to or larger than the threshold, for example. Subsequently, the number is counted in the rightward direction and the sum is calculated. By doing so, the horizontal connection length of the mesh M can be calculated. Moreover, the number of continuous meshes M of which the print ratio is equal to or larger than the threshold may be counted from the left side for all meshes M, and the numbers of continuous meshes may be filled into the meshes M from the count start position to the count end position. Furthermore, the edges of the two-valued mesh image illustrated in
The connection length may be calculated after creating the two-valued mesh image illustrated in
The necessary control temperature is allocated to each mesh image on the basis of the connection information calculated in Step 2 and by referring to a separately set table. In Step 2, vertical and horizontal connection size information is calculated for each mesh M(m,n). On the basis of the calculation result, in Step 3, by referring to a control temperature setting table set separately as illustrated in Table 1, a value obtained by referring to the vertical connection length Lh(m,n), the horizontal connection length Lv(m,n), and the table is set to each mesh M(m,n). For example, when the vertical connection length is 3 and the horizontal connection length is 2, temperature T3_2 is allocated to the mesh M(m,n) by referring to Table 1. For meshes M(m,n) in which a value of 0 is filled in
In the present embodiment, although the control temperature value is set directly in the table, a correction value for a reference control temperature may be used, a value correlated with the necessary control temperature may be used, and a value correlated with the fixing performance may be used.
A control temperature setting table used actually in the present embodiment is illustrated as below.
Correction is applied to the control temperature necessary for fixing the respective meshes M(m,n) allocated in Step 3. In the present embodiment, two corrections including transport direction correction A and toner print history correction B are performed.
The control temperature allocated to the respective meshes M(m,n) is corrected depending on the position in the transport direction of the mesh M. A correction value TA(m,n) is applied to the respective meshes M(m,n) as below depending on the position m from the leading end of the recording material.
When a fixing operation is performed on a portion on which toner is printed, since heat is taken away from a fixing film to melt down the toner, the film temperature in the corresponding portion decreases. When a fixing operation is performed after the film in the portion where the temperature has decreased makes one rotation, since the film temperature in the corresponding portion has decreased a little, it is necessary to set the control temperature to be high. That is, the control target temperature in a mesh on an upstream side on which the mesh makes contact with a film region which already made contact with a mesh on a downstream side in the transport direction of a recording material among meshes of image data is corrected to a temperature higher than that before the correction. In the present embodiment, when print data is present in meshes M(m-57,n), M(m-114,n), M(m-171,n), and M(m-228,n), the film cycle before of a certain M(m,n), correction is performed with respect to the mesh M(m,n). That is, 57 meshes correspond to approximately a circumferential length (the length in the transport direction of the recording material) of the film.
A correction value of a mesh M(m,n) at a certain position (m,n) is calculated. A correction value TB(m,n) is calculated by the following equation.
a, b, c, and d are coefficients, and in the present embodiment, are set such that a=3.0, b=1.5, c=1.0, and d=0.5. This calculation process is not performed when a calculation target is outside the region of a recording material. For example, when m of a mesh M is between 58 and 114, although meshes M, one film cycle before of the mesh M are present, since meshes M, two film cycles before of the mesh M are not present, the calculation is performed up to the first term on the right side.
A temperature required for fixing Tf(m,n) after correction of each mesh M(m,n) is calculated as below.
Tf(m,n)=T(m,n)+TA(m,n)+TB(m,n) Equation 3
In Step 4, the largest value of the temperature required for fixing Tf(m,n) after correction of each mesh M(m,n) is calculated for meshes M in one page of a recording material, and the largest value is used as a control temperature Tp necessary for that page.
For example, when a solid black pattern is printed on an entire surface of an A4-size recording material, T=192° C. referring to Table 2, TA=2° C. referring to Table 3, and TB=6° C. referring to Equation 2 for meshes near the trailing end of the recording material. Moreover, Tf=200° C. referring to Equation 3, and a control temperature of the page is Tp=200° C. Similarly, when a solid white pattern is printed, T=180° C. referring to Table 2, TA=2° C. referring to Table 3, and TB=0° C. referring to Equation 2 for meshes near the trailing end of the recording material. Moreover, Tf=182° C. referring to Equation 3, and a control temperature of the page is Tp=182° C.
In the present embodiment, fixing temperature control to be described later is performed using the temperature required for fixing Tp of a detection image calculated according to the above-described steps.
When a print command and an image is transmitted to the controller interface 305 by the host computer 300, the image analysis portion 401 calculates the control temperature Tp on the basis of the image information received from the image processing portion 303. Subsequently, the engine control portion 302 starts a print operation on the basis of a signal from the controller portion 301. When a print operation starts, the apparatus starts operating at the setting temperature of 180° illustrated in
Subsequently, as a fixing operation of the present embodiment, the control temperature Tp calculated by the method described in the present embodiment, corresponding to a first page of images is received at a timing one rotation of the fixing film before a timing at which the leading end of the first page of a recording material enters the fixing nip, and the control temperature is changed. The control temperature for the first page of a recording material indicated by a solid line in
If the control temperature is changed to a low temperature from a timing at which the leading end of the recording material enters the fixing nip, since the film is warmed up due to the pre-rotation control temperature, the amount of heat that the leading end of the recording material receives actually becomes too large. Therefore, in the present embodiment, the control temperature is changed from the pre-rotation control temperature of 180° C. to Tp−20° C. at a timing at which the recording material enters the fixing nip and which is before one rotation of the fixing film. That is, the pre-rotation control temperature before one rotation of the film is changed from 180° C. to 170° C. During passage of the sheet, the control temperature is set to the calculated control temperature Tp of the first page.
After that, when the trailing end of the recording material passes through the fixing nip, the control temperature is changed depending on the control temperature Tp calculated by the method described in the present embodiment, corresponding to the toner image printed on a subsequent recording material.
By performing control in the above-described manner, in the present embodiment, it is possible to provide an image forming apparatus which provides satisfactory fixing performance regardless of an image pattern and suppresses unnecessary power consumption to provide excellent energy saving properties.
Next, the advantages of the present embodiment will be described.
First, the flow of heat when images with a small line width and a large line width are printed on a recording material P and a fixing operation is performed will be described with reference to
Next, a conventional detection method and a detection method of the present embodiment when an image pattern is printed are compared using
Table 4 illustrates the examination results of the temperature necessary for fixing the three images. The image a can be fixed with a lower control temperature than that of the image b. As described above, this is because the fixing performance of such a discrete pattern as the image a is better than that of such a fixed pattern as the image b due to whirling of heat. However, when the interval is small as in the image c, since a sufficient whirling effect of heat is not obtained, a high control temperature is necessary similarly to the image b.
Next, an image analysis method will be compared. Comparative example 1 is a case in which an image is detected with a largest toner laid-on level, Comparative example 2 is a case in which an image is detected with a print ratio, and Comparative example 3 is a case in which an image is detected with the size of a solid black pixel. Table 4 illustrates how a control temperature can be set for the respective images when the images are detected by the respective methods. Since an image is detected with a largest toner laid-on level in Comparative example 1, different detection results are not obtained for three images having the same largest toner laid-on level, and the control temperature setting cannot be changed. Since an image is detected with a toner print ratio in Comparative example 2, different detection results are not obtained for three images having the same area, and the control temperature setting cannot be changed. Although the image b can be detected appropriately in Comparative example 3 since the size of the solid black pixel is larger than that of the image a. However, since the image c is detected as a solid black pattern having a small size, the control temperature of the image c is set similarly to the image a. As a result, fixing failures may occur when a pattern like the image c is printed.
In the method of the present embodiment, as described above, an original image is divided into meshes M including 24 by 24 pixels, and an appropriate control temperature is allocated according to the connection information of the mesh image in which the calculated average print ratio of the respective meshes M is equal to or larger than the threshold Th. Since the connection length of the mesh image of the images b and c is large as compared to the image a, the images b and c can be appropriately detected separately. When the images b and c are converted to mesh images and are cut by the threshold Th, a small interval of the image c is filled. Therefore, substantially similar detection results are obtained for the images b and c without being hypersensitive to a very small space. Therefore, a high control temperature can be set to the images b and c. That is, an appropriate control temperature can be set for the three images.
As described above, the image forming apparatus of the present embodiment can set the control temperature appropriately for the respective images by performing image analysis according to the above-described method and control the fixing temperature optimal for the image pattern. Moreover, since a necessary control temperature is allocated to respective meshes, correction can be performed easily depending on a position. In this way, it is possible to provide an image forming apparatus having satisfactory energy saving performance while obtaining a satisfactory fixing performance regardless of an image pattern.
Although printing is performed by connecting the host computer 300 to the image forming apparatus 100 of the present embodiment, printing may be performed by connecting a computer connected on a network or a print server instead of the host computer 300. Although the image processing portion 303 on the controller 301 performs the image analysis and calculates the control temperature correction amount, the present invention is not limited thereto. Either the image analysis or the calculation of the control temperature correction amount may be performed by a host computer, a printer on a network, and a program possessed by a print server.
Although the size of the mesh M set in the present embodiment is 24 pixels by 24 pixels, the present embodiment is not intended to restrict the region but the size and the shape of the detection region may be changed according to the characteristics of the image forming apparatus.
The control temperature correction calculated in the present embodiment may be changed on the basis of a fixing mode for determining the control temperature, ambient environment information detected by an environment detection unit (not illustrated), a recording material type detected by a media sensor (not illustrated).
In the fixing control of the present embodiment, although the control temperature only is changed, the gain of PID control and an offset electric energy used in the control temperature control may be changed.
In the fixing control of the present embodiment, although the control temperature is changed before a recording material including a detection image enters the fixing nip, the control temperature may be changed before the toner image of an image analyzed by the image analysis unit enters the fixing nip and may be changed in an earlier stage.
In the present embodiment, although one detection result is calculated for one page, there is no limitation thereto. For example, meshes may be grouped in respective regions in the transport direction corresponding to the fixing film cycle, the optimal control temperature in the respective groups may be calculated, and the control temperature in the page may be changed.
In the present embodiment, although the calculation processing procedure of the image analysis portion 401 has been performed on an image on which the processing of the other image processing portions 402 has been finished, the calculation process may be performed before the processing of the other image processing portions 402 is performed.
Embodiment 2 of the present invention will be described. In Embodiment 2, another correction is applied to a detection result according to a mesh position n in the horizontal direction in addition to Embodiment 1. The fixing performance at both ends of a recording material P may be poor than the central portion depending on the configuration of a fixing apparatus to be used and the size of the recording material P being passed. Moreover, when a member having a large heat capacity is locally in contact with a portion of a rear surface of the heating heater 11, the flash-side pool address space of the corresponding portion may be poor than the other portions. For example, a configuration in which a safety element such as a thermo switch or a temperature fuse that operates in response to abnormal heating of a heater to interrupt the supply of electric power to the heater comes into direct contact with the heater or indirectly with a holding member or the like disposed therebetween may be used. It is necessary to set the control temperature necessary for fixing the corresponding portion to be high.
Hereinafter, Embodiment 2 as countermeasures against decrease in the fixing performance at both ends of the recording material P will be described. A basic configuration of the image forming apparatus of Embodiment 2 and processes other than image analysis are similar to those of Embodiment 1 and the description thereof will be omitted. In the present embodiment, a correction method when the fixing performance at an end is poor will be described.
The correction method will be described according to the flowchart of a temperature required for fixing calculation method illustrated in
Steps 1 to 4 are similar to those of Embodiment 1 and the description thereof will be omitted.
In the present embodiment, another correction is applied to the detection results of the temperature required for fixing Tf(m,n) of each mesh M(m,n), to which correction in the transport direction has been made in Step 4, according to the position in the longitudinal direction. Specifically, correction TC(m,n) of the present embodiment is applied according to the following equation. In the present embodiment, correction is performed when a recording material has the LTR size (216 mm×279 mm) which is the largest sheet passing width. The present control is not effective in A4-size sheets since the A4-size sheet has a narrower width than the LTR-size sheet and the fixing performance at an end does not decrease.
Tf′(m,n)=Tf(m,n)+TC(m,n)
TC(m,n)=5 (if n≤−100, 100≤n)
TC(m,n)=0 (if −100<n<100) Equation 5
This equation means that the temperature required for fixing is corrected by 5° C. for a mesh M(m,n) positioned in the regions that are 3 mm from the left and right ends of an image printing region which is a region of an LTR-size recording material excluding the margin of 5 mm from the left and right ends of the recording material. That is, when such a rectangular image as in
Similarly to Embodiment 1, in Step 5, the largest value of the temperature required for fixing Tf′(m,n) after correction of each mesh M is calculated for meshes M in one page of a recording material, and the largest value is used as a control temperature Tp necessary for that page.
When the calculation process is performed as in the present embodiment, the control temperature may be increased when an image having a poor fixing performance is present in the extreme ends as illustrated in
Although the temperature required for fixing at the ends is corrected in the present embodiment, similar advantages can be obtained when the necessary control temperature is calculated for respective rectangular regions, and the optimal control temperature is calculated for respective regions and transmitted to an engine control portion so that the engine control portion performs correction and determines a final control temperature.
Embodiment 3 of the present invention will be described. In Embodiment 3, another correction is applied to a detection result according to a print ratio of a region in which a temperature detection element is positioned in addition to Embodiment 1. When an image is formed in the region of a temperature detection element, a large amount of electric power is supplied to maintain the temperature constant since heat is taken away from the film to melt down toner. Variations in the fixing performance associated with this are estimated and the control temperature is set appropriately. A basic configuration of the image forming apparatus of Embodiment 3 and the image analysis process are similar to those of Embodiment 1 and the description thereof will be omitted.
The correction method will be described according to the flowchart of a method for calculating a temperature required for fixing illustrated in
Steps 1 to 5 are similar to those of Embodiment 1 and the description thereof will be omitted.
Processes until the temperature required for fixing Tp is calculated are similar to those of Embodiment 1.
In the present embodiment, a print ratio is calculated at the position of a rectangle corresponding to a thermistor portion. Specifically, an average print ratio Rtm of meshes M in a range where the rectangle position n is within tm±5 is calculated with respect to a mesh position tm in the longitudinal direction corresponding to the thermistor portion. In the present embodiment, the position number tm of the rectangular mesh M of the thermistor is 25.
Here, e is a coefficient and is 3 in the present embodiment. When the print ratio of a thermistor portion is the largest value (that is, 100%), since a large amount of electric power is supplied, it is possible to fix an image with a temperature that is 3° C. lower than the control temperature. Therefore, the temperature required for fixing Tp is corrected according to the print ratio Rtm of the thermistor portion.
When the calculation process is performed as in the present embodiment, a low control temperature can be set when a vertical stripe of a solid black image is present in the region of the thermistor portion D as in
In the present embodiment, although an average value in the entire transport direction of the print ratio Rtm of the thermistor portion D is calculated, there is no limitation thereto. For example, the print ratio may be calculated at respective positions in the transport direction (for example, for respective film cycles), a correction value may be calculated for the respective print ratios, and the temperature required for fixing Tf(m,n) after correction of the respective meshes M(m,n) may be corrected according to the position in the transport direction.
Similar advantages can be obtained when the calculation result of the print ratio of the thermistor portion is transmitted to an engine control portion without correcting the temperature required for fixing so that the engine control portion performs correction and determines the control temperature.
In Embodiment 1, the threshold Th is set to 50% in Step 2 and the connection length of the mesh M of which the print ratio is equal to or larger than the threshold is calculated. In Embodiment 4 of the present invention, in order to detect a thin halftone image in addition to Embodiment 1, a second threshold Th2 is set, the connection length of meshes M(m,n) having the print ratio R(m,n) which is equal to or larger than the threshold Th2 and smaller than the threshold Th is calculated, and the temperature required for fixing is calculated. That is, the threshold Th is set as a first threshold, the size of connection in which meshes having the print ratio which is equal to or larger than the threshold Th2 and smaller than the threshold Th are continuously adjacent to each other as second meshes having the print ratio which is equal to or larger than the second threshold and smaller than the first threshold is acquired and is used for setting the temperature required for fixing. In this way, it is possible to set the control temperature appropriately for a thin halftone image. A basic configuration of the image forming apparatus of Embodiment 4 and the image analysis process are similar to those of Embodiment 1 and the description thereof will be omitted.
A
The respective steps of the flowchart of the method for calculating a temperature required for fixing illustrated in
An original image (600 dpi) as illustrated in
The connection information (vertical and horizontal connection lengths) of meshes M having a print ratio R(m,n) of 50% or more as the threshold Th is calculated from the mesh image. Moreover, the second threshold Th2 is set to 10%, and the connection length of the meshes M having the print ratio which is equal to or larger than the threshold Th2 and smaller than the threshold Th is calculated.
A vertical connection length and a horizontal connection length are client device for meshes M having the print ratio satisfying the thresholds from the mesh image illustrated in
Each of the three-valued meshes M is defined as E2(m,n).
E2(m,n)=1 (if R(m,n)≥Th)
0.5 (if Th2≤R(m,n)<Th)
0 (if R(m,n)<Th2) Equation 9
The vertical connection length Lv(m,n) and the horizontal connection length Lh(m,n) are calculated according to a method similar to that of Embodiment 1.
The necessary control temperature is allocated to each mesh image on the basis of the connection information calculated in Step 2 and by referring to a separately set table. In Step 2, vertical and horizontal connection size information is calculated for each mesh M(m,n). On the basis of the calculation result, in Step 3, by referring to a control temperature setting table set separately as illustrated in Tables 1 and 5, a value obtained by referring to the vertical connection length Lh(m,n), the horizontal connection length Lv(m,n), and the tables is set to each mesh M(m,n). For the three-valued meshes M in
For example, when the vertical connection length is 1 and the horizontal connection length is 2, temperature T1_2 is allocated to the mesh M in which the value of 1 is filled in
Basically, the control temperature setting table 2 for low print ratio in Table 5 is set so that a relatively high control temperature is allocated to a mesh M having a large connection length. However, as compared to the control temperature setting table for high print ratio in Table 1, a lower temperature is set in the control temperature setting table for low print ratio in Table 5. However, the control temperature may be set appropriately when it is necessary to increase the control temperature for low print ratio depending on the toner used or the characteristics of the fixing apparatus.
In the control temperature setting table 2 for low print ratio, since the fixing performance does not change greatly for an image having a connection length of 10 mm or more, the same control temperature as that of an image having a connection length of 10 meshes is set for the mesh having a connection length of 10 meshes or more. However, the table may be changed appropriately depending on a fixing configuration or the like.
In the present embodiment, although the control temperature value is set directly in the table, a correction value for a reference control temperature may be used, a value correlated with the necessary control temperature may be used, and a value correlated with the fixing performance may be used.
The control temperature setting table 2 used actually in the present embodiment is illustrated as below.
Correction is applied to the control temperature necessary for fixing the respective meshes M(m,n) allocated in Step 3. In the present embodiment, two corrections including transport direction correction A and toner print history correction B are performed.
Correction similar to that of Embodiment 1 is applied depending on the position in the transport direction.
Similarly to Embodiment 1, correction is applied when an image is printed before the film cycle of each mesh M.
A correction value of a mesh M(m,n) at a certain position (m,n) is calculated. A correction value TB(m,n) is calculated by the following equation.
a, b, c, and d are coefficients, and similarly to Embodiment 1, are set such that a=3.0, b=1.5, c=1.0, and d=0.5. This calculation process is not performed when a calculation target is outside the region of a recording material. In Equation 10, the control temperature is corrected by 3° C. for the mesh M in which a mesh M having a high print ratio is present before one rotation of the film, for example. Moreover, the control temperature is corrected by 1.5° C. for the mesh M in which a mesh M having a low print ratio is present before one rotation of the film, for example.
A temperature required for fixing Tf2(m,n) after correction of each mesh M is calculated as below.
Tf2(m,n)=T2(m,n)+TA(m,n)+TB2(m,n) Equation 11
A largest value of the temperature required for fixing Tf after correction of each mesh M in Step 4 is calculated for the mesh M in one page of a recording material, and the largest value is used as the control temperature Tp necessary for that page.
In the present embodiment, the control temperature is corrected using the temperature required for fixing Tp for the detection image calculated according to the steps to be described later. The fixing temperature control sequence performed by the fixing temperature control portion is similar to that of Embodiment 1, and the description thereof will be omitted.
By performing detection in the above-described manner, in addition to the advantages of Embodiment 1, it is possible to set the temperature required for fixing appropriately for a halftone image having a low print ratio and to control the fixing temperature optimally for an image pattern. In this way, it is possible to provide an image forming apparatus having satisfactory energy saving performance while obtaining a satisfactory fixing performance regardless of an image pattern.
The configurations of the respective embodiments can be combined with each other.
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 such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2018-019631, filed on Feb. 6, 2018, which is hereby incorporated by reference herein in its entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2018-019631 | Feb 2018 | JP | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 9075356 | Ooyanagi | Jul 2015 | B2 |
| 9436147 | Yamazaki | Sep 2016 | B2 |
| 20180067427 | Obayashi | Mar 2018 | A1 |
| Number | Date | Country |
|---|---|---|
| 2008-268784 | Nov 2008 | JP |
| 2012073441 | Apr 2012 | JP |
| 2014-074894 | Apr 2014 | JP |
| 2015-145969 | Aug 2015 | JP |
| 2016-004231 | Jan 2016 | JP |
| 2016136225 | Jul 2016 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20190243292 A1 | Aug 2019 | US |
