Patent Grant
9217962
The present invention relates to image forming apparatuses including copying machines and laser printers.
An electrophotographic color image forming apparatus has independent image forming parts for forming yellow, magenta, cyan, and black images. The images of these colors are consecutively transferred from the image forming parts to an intermediate transfer belt, and then the images are collectively transferred from the intermediate transfer belt to a recording media. Thus, the electrophotographic color image forming apparatus achieves high speed printing.
The image forming parts for these colors each include a photosensitive drum, which serves as an image bearing member, a charging member, which charges the photosensitive drum, and a developing unit, which develops a toner image onto the photosensitive drum. The charging member of each image forming part comes into contact with the corresponding photosensitive drum at a predetermined pressure, and charges the surface of the photosensitive drum with a charging voltage applied from a charging voltage source in such a manner that the surface uniformly has a predetermined potential with a predetermined polarity.
The developing unit of each image forming part attaches toner to an electrostatic latent image formed on the corresponding photosensitive drum and then develops the latent image into a toner image (visible image).
Toner images developed onto the photosensitive drums of the image forming parts are first-transferred to the intermediate transfer belt by first transfer rollers, which are opposite the photosensitive drums with the intermediate transfer belt being interposed therebetween and which serve as first transfer portions. The first transfer rollers are connected to corresponding first-transfer voltage sources.
The toner images that have been first-transferred to the intermediate transfer belt are then second-transferred to a transfer medium by a second transfer unit. A second transfer roller that serves as the second transfer unit is connected to a second-transfer voltage source.
PTL 1 discloses an apparatus that includes four first transfer rollers connected to four corresponding first-transfer voltage sources. PTL 2 discloses an apparatus that performs control so that, before an image forming operation, a transfer voltage to be applied to each first transfer roller is changed in accordance with the properties of the intermediate transfer belt and the first transfer roller, including a sheet-feeding durability and a resistance that varies due to environmental changes.
PTL 3 discloses an image forming apparatus of a known type in which a residual toner remaining on an intermediate transfer belt is charged by a charging member and then transferred to an image forming part in a first transfer portion to be recovered. In this structure, the image forming part recovers the residual toner on the intermediate transfer belt. Thus, the need for a waste-toner container dedicated to the intermediate transfer belt is eliminated, and a compact apparatus is achieved, accordingly.
However, the above-described image forming apparatuses have the following problems. With a known method of setting first transfer voltages, each image forming part is required to set an appropriate first transfer voltage, and thus multiple voltage sources are needed. This increase in the number of voltage sources resultantly increases the size and the cost of the image forming apparatuses.
Moreover, since an appropriate first transfer voltage is calculated on the basis of the varying resistance of each first transfer portion before the image forming operation, it may take a long time until image formation is started. Further, when the first transfer portion in each image forming part presses the corresponding photosensitive drum via the intermediate transfer belt at a predetermined pressure to supply a current to the photosensitive drum, the photosensitive drum being subjected to the load may wear earlier than expected.
Further, when the toner-charging member charges the residual toner that has not arrived at the first transfer portion, the intermediate transfer belt is also charged at the same time. This charging may raise the voltage of the intermediate transfer belt and affect the transfer unit performance in the case of a first transfer of the subsequent toner image.
In view of the above problems, the present invention provides an image forming apparatus that includes fewer voltage sources, is made compact, and is capable of recovering a residual toner remaining on an intermediate transfer belt by use of image forming parts while maintaining an appropriate first transfer performance of the transfer unit.
Image forming apparatuses according to embodiments of the present invention have the following structures to solve the above problems.
With an image forming apparatus according to an embodiment of the present invention, a current supply member supplies a current in a rotational direction of an intermediate transfer belt, and thus multiple first transfer portions no longer need corresponding voltage sources. Even when a toner-charging member supplies a current to the intermediate transfer belt, the potential of the intermediate transfer belt can be maintained at a predetermined potential. Thus, the apparatus is made compact and operates at a low cost.
Embodiments of the present invention will be exemplarily described in detail below with reference to the drawings. Note that components described in the embodiments are mere examples, and the scope of the present invention is not limited to these components.
The image forming parts 1a, 1b, 1c, and 1d respectively include photosensitive drums 2a, 2b, 2c, and 2d, which serve as image bearing members. In the first embodiment, the photosensitive drums 2a, 2b, 2c, and 2d each have a drum base (not illustrated), which is a negatively-charged organic photosensitive member made of aluminum or the like, and a photosensitive layer (not illustrated) formed on the drum base. The photosensitive drums 2a, 2b, 2c, and 2d are rotatably driven by a driving unit (not illustrated) at a predetermined process speed.
Charging rollers 3a, 3b, 3c, and 3d, which serve as charging members, and developing units 4a, 4b, 4c, and 4d are respectively arranged around the photosensitive drums 2a, 2b, 2c, and 2d. Further, drum cleaning devices 6a, 6b, 6c, and 6d are respectively arranged around the photosensitive drums 2a, 2b, 2c, and 2d. Exposure units 7a, 7b, 7c, and 7d are respectively arranged above the photosensitive drums 2a, 2b, 2c, and 2d. The developing units 4a, 4b, 4c, and 4d respectively contain a yellow toner, a magenta toner, a cyan toner, and a black toner. The toners used in the first embodiment are normally charged with a negative polarity.
A rotatable endless intermediate transfer belt 8, which serves as an intermediate transfer member, is disposed so as to be opposite the image forming parts. The intermediate transfer belt 8 is supported by a driving roller 11, an opposing roller for second transfer 12, and a tension roller 13 (these three rollers serve as support members). When the driving roller 11 connected to a motor (not illustrated) is driven, the intermediate transfer belt 8 is rotated (moved) in the direction indicated by an arrow in
The driving roller 11, the opposing roller for second transfer 12, and the tension roller 13 are grounded via resistors with predetermined values of resistance. In the first embodiment, resistors with three values of resistance of 1 GΩ, 100 MΩ, and 10 MΩ are employed. The resistance of the rubber layers of the driving roller 11 and the opposing roller for second transfer 12 is far smaller than 1 GΩ, 100 MΩ, and 10 MΩ, and thus the electric effect of the resistance of these rubber layers is negligible.
An elastic roller with a volume resistivity of 107 to 109 Ωcm and a rubber hardness of 30° (measured by asker C durometer) is employed as the second transfer roller 15. The second transfer roller 15 is pressed against the opposing roller for second transfer 12 at a total pressure of approximately 39.2 N via the intermediate transfer belt 8. The second transfer roller 15 is driven to rotate by rotation of the intermediate transfer belt 8. Further, a voltage of −2.0 to 7.0 kV is applicable to the second transfer roller 15 from a transfer power source 19. As will be described below, a voltage is applied to the second transfer roller 15 according to the first embodiment from the transfer power source 19 that is a voltage source used in common for first transfers and second transfers. The second transfer roller 15 is a current supply member that supplies a current in the circumferential direction of the intermediate transfer belt 8. Thus, the transfer power source 19 is a power source that applies a voltage, used for transfers, to the current supply member.
A toner charging unit (also referred to as a cleaning unit) 75 is disposed on the outer side of the intermediate transfer belt 8. The toner charging unit 75 removes and recovers a residual toner remaining on the surface of the intermediate transfer belt 8 after a first transfer is complete. A cleaning brush 71, which serves as a charging member, included in the toner charging unit 75 is made of almost densely arranged nylon fibers having an electric conductivity of 106 to 109 Ωcm. A tip end portion of the cleaning brush 71 is located so that the tip end portion is pressed into the surface of the intermediate transfer belt 8 by an amount of 1.0 mm.
The length of the cleaning brush 71 in the longitudinal direction, which traverses the moving direction of the surface of the intermediate transfer belt 8, is approximately equivalent to the width of a formable-image region, which extends in the longitudinal direction of the cleaning brush 71, formed on the intermediate transfer belt 8. The cleaning brush 71 brushes the surface of the intermediate transfer belt 8 with the movement of the intermediate transfer belt 8. A voltage of −2.0 to +2.0 kV is applicable to the cleaning brush 71 from a cleaning power source (charging power source) 72, which serves as a charging power source.
A fixing device 17 including a fixing roller 17a and a pressure roller 17b is arranged further downstream, in the rotational direction of the intermediate transfer belt 8, than the second transfer unit, in which the opposing roller for second transfer 12 and the second transfer roller 15 come into contact with each other.
Next, an image forming operation will be described.
Once a controller (not illustrated) outputs a start signal to start an image forming operation, transfer media (recording media) are fed one by one from a cassette (not illustrated) and conveyed to a registration roller (not illustrated). At this time, the registration roller is in the stationary state and the tip end of the transfer medium is held immediately before the second transfer unit. When the start signal is output, the photosensitive drums 2a, 2b, 2c, and 2d of the image forming parts 1a, 1b, 1c, and 1d start rotating at a predetermined process speed. In the first embodiment, the charging rollers 3a, 3b, 3c, and 3d uniformly charge the photosensitive drums 2a, 2b, 2c, and 2d, respectively, with a negative polarity. The exposure units 7a, 7b, 7c, and 7d respectively scan and expose the photosensitive drums 2a, 2b, 2c, and 2d to laser beams and thus form electrostatic latent images.
Then, firstly, the developing unit 4a applied with a development voltage with the same polarity (negative polarity) as the charging polarity of the photosensitive drum 2a attaches a yellow toner to the electrostatic latent image formed on the photosensitive drum 2a to make the latent image visible as a toner image. The charging amount and the exposure amount are adjusted in such a manner that an image portion of each photosensitive drum has a potential of −500 V after being charged by the corresponding charging roller, and a potential of −100 V after the exposure by the corresponding exposure unit. The developing bias is set to −300 V. The process speed is set to 250 mm/sec. The width of a formable image, which extends in a direction perpendicular to the transfer direction (rotational direction), is set to 215 mm, the quantity of charge in the toner is set to −40 μC/g, and the amount of toner placed on an image attached portion of the photosensitive drum is set to 0.4 mg/cm2.
The yellow toner image is first-transferred onto the rotating intermediate transfer belt 8. Here, portions or positions of the intermediate transfer belt 8 that are opposite the photosensitive drums 2a, 2b, 2c, and 2d and to which the photosensitive drums 2a, 2b, 2c, and 2d transfer toner images are referred to as first transfer portions. The intermediate transfer belt 8 has multiple first transfer portions that correspond to the multiple image bearing members. A structure, in the first embodiment, for first-transferring the yellow toner image onto the intermediate transfer belt 8 will be described below.
The toner images held on the multiple image bearing members are first-transferred to the multiple first transfer portions of the intermediate transfer belt 8 so as to correspond to the multiple image bearing members. As illustrated in
Along with rotation of the intermediate transfer belt 8, the portion to which the yellow toner image is transferred moves closer to the image forming part 1b. Likewise, the image forming part 1b also transfers a magenta toner image formed on the photosensitive drum 2b onto the yellow toner image placed on the intermediate transfer belt 8, in a superposing manner. In the same manner, cyan and black toner images that are respectively formed on the photosensitive drums 2c and 2d of the image forming parts 1c and 1d are sequentially superposed on the yellow and magenta toner images that have been transferred onto the intermediate transfer belt 8 in a superposing manner. Thus, a full-color toner image is formed on the intermediate transfer belt 8.
The registration roller (not illustrated) conveys a transfer medium P to the second transfer unit at the timing when a tip end portion of the full-color toner image on the intermediate transfer belt 8 arrives at the second transfer unit. The full-color toner image on the intermediate transfer belt 8 is collectively second-transferred to the transfer medium P by the second transfer roller 15, which is a second transfer component to which a second transfer voltage (a voltage with a polarity that is opposite to that applied to the toners, or with a positive polarity) is applied. The transfer medium P on which the full-color toner image has been formed is conveyed to the fixing device 17. The full-color toner image is heated and pressurized by the fixing device 17 that includes the fixing roller 17a and the pressure roller 17b, and is thermally fixed to the surface of the transfer medium P. Then, the transfer medium P is output to the outside. In the first embodiment, a residual toner that remains on the intermediate transfer belt 8 without being transferred to the transfer medium P is charged by the cleaning unit 75 and recovered from the first transfer portions by the photosensitive drums 2a, 2b, 2c, and 2d.
The image forming apparatus according to the first embodiment is characterized in that toner images are first-transferred from the photosensitive drums 2a, 2b, 2c, and 2d to the intermediate transfer belt 8 without the opposed rollers 5a, 5b, 5c, and 5d having voltages applied thereto, unlike in the case of the first transfer rollers 55a, 55b, 55c, and 55d illustrated in
Now, a volume resistivity, a surface resistivity, and a circumferential resistance of the intermediate transfer belt 8 will be described below for describing the characteristics of the image forming apparatus according to the first embodiment. The definition and a method of measuring the circumferential resistance will be described below.
Volume Resistivity and Surface Resistivity of Intermediate Transfer Belt
The intermediate transfer belt 8 according to the first embodiment has a base layer obtained by dispersing carbon in a polyphenylene sulfide (PPS) polymer having a thickness of 100 μm and by being subjected to adjustment of the electrical resistance. Other adoptable polymers include polyimide (PI), polyvinylidene fluoride (PVdF), nylon, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polycarbonate, polyetheretherketone (PEEK), and polyethylene naphthalate (PEN).
The intermediate transfer belt 8 has a multilayer structure. Specifically, the intermediate transfer belt 8 has a highly resistant acrylic surface layer with a thickness of 0.5 to 3 μm on the outer side of the base layer. The highly resistant surface layer is provided to decrease the difference in amount of current in the longitudinal direction of the second transfer unit, i.e., the difference between the amount of current flowing through a sheet-feeding region of the second transfer unit and the amount of current flowing through a non-sheet-feeding region of the second transfer unit, and to thus obtain a desired performance of the transfer unit in the case of a second transfer of toner images to a small sheet.
Next, a method of producing an intermediate transfer belt will be described. In the first embodiment, an inflation forming method is adopted as the production method. A compound of PPS that is the base material and carbon black that is electric conductive powders or the like are melted and mixed by a twin-shaft kneader. The obtained mixture is extruded by an annular die and thus formed into a belt.
The surface coat layer is formed by spray-coating a ultraviolet curable resin on the surface of the formed endless belt, drying the resin, and then curing the resin with ultraviolet irradiation. The amount of resin used for coating is regulated to be within a range of 0.5 to 3 μm because the coat layer cracks more easily if it is too thick.
Although carbon black is adopted as an electric conductive powder in the first embodiment, the present invention is not limited to any particular additive that is mixed for adjusting the electrical resistance of the intermediate transfer belt 8. Examples of an electric conductive filler that can adjust the resistance include various conductive metal oxides in addition to carbon black. Examples of a non-filler additive for adjusting the resistance include a low-molecular-weight ionic conductor such as metal salts and glycols, an antistatic resin having an ether bond or a hydroxyl in its molecule, or an organic macromolecular compound having electric conductivity.
As the amount of carbon in the belt increases, the belt has a lower resistance. If the belt were to contain an excessively large amount of carbon, the belt would end up with insufficient strength and thus crack more easily. In the first embodiment, the resistance of the belt is lowered to an extent that the strength of the belt falls within a range that is suitable for the image forming apparatus.
The Young's modulus of the intermediate transfer belt 8 according to the first embodiment is approximately 3000 MPa. The Young's modulus E was measured by a method of determining the tensile/elastic modulus of JIS-K7127, and the thickness of the measured specimen was set to 100%.
Table 1 shows relative amounts of carbon in a base material for Belts A to E (referred to as “a relative ratio”).
Table 1 shows the amount of added carbon and the absence or presence of the surface coat layer. For example, Table 1 shows that the amount of carbon in Belt B is 1.5 times that in Belt A, and the amount of carbon in Belt C is two times that in Belt A. Belt A, Belt B, and Belt C include surface coat layers, while Belt D and Belt E are single-layer belts. Belt B and Belt D have the same relative ratio of carbon. Belt C and Belt E also have the same relative ratio of the amount of carbon.
For comparison, a comparative belt made of polyimide was also prepared by changing the relative ratio of carbon and by being subjected to resistance adjustment. The comparative belt has a relative ratio of carbon of 0.5 and a volume resistivity of 1010 to 1011 Ωcm. The comparative belt has a resistance that is general for typical intermediate transfer belts.
Measurement results of the volume resistivity and the surface resistivity for the comparative belt and Belts A to E are shown below.
Measurement was performed on the comparative belt and Belts A to E by use of Hiresta UP (MCP-HT450) that is a resistivity meter produced by Mitsubishi Chemical Analytech Co., Ltd. Table 2 shows the measurement results of the volume resistivity and the surface resistivity (of the outer surface of each belt). The measurement was performed by a measurement method of JIS-K6911 and by using a conductive rubber as an electrode so that the electrode and the surface of each belt could be in favorable contact with each other. The measurement was performed by applying each of voltages of 10 V and 100 V to each belt for 30 seconds.
When a voltage of 100 V was applied to the comparative belt, the volume resistivity was determined to be 1.0×1010 Ωcm and the surface resistivity was determined to be 1.0×1010 Ω/square. However, when a voltage of 10 V was applied to the comparative belt, the current flowing through the belt was too small for the meter to determine the volume resistivity, and thus the meter showed “over”.
On the other hand, when a voltage of 100 V was applied to each of Belts B, C, and D, the meter showed “under”, which indicates that, due to the low resistance of the belt, the current flowing through the low-resistant belt was too large for the meter to determine the volume resistivity. When a voltage of 100 V was applied to Belt B, the surface resistivity was determined to be 2.0×108 Ω/square, whereas when a voltage of 100 V was applied to each of Belts C and D, the meter showed “under”.
As shown in Table 2, when a voltage of 10 V was applied to Belt A, the meter failed to determine the volume resistivity and the surface resistivity. The surface resistivity of Belt A that was obtained when a voltage of 100 V was applied to Belt A is higher than that of the comparative belt obtained under the same conditions. This is due to the presence of the coat layer. Accordingly, it is found that Belt A that has a highly resistant surface coat layer has a higher electrical resistance than the comparative belt that has no surface coat layer.
By comparing Belt B and Belt D, and Belt C and Belt E, it is found that the presence of the coat layer increases the resistance. In addition, by comparing Belt B and Belt C, and Belt D and Belt E, it is found that the increase in the amount of carbon lowers the resistance. The meter was unable to determine the resistivity of Belt E under all the conditions since the resistance of Belt E was too low.
The intermediate transfer belt employed in the first embodiment is required to have a volume resistivity or a surface resistivity that falls within a range of values denoted by “under” in Table 2. For this reason, measurement on the resistance of the intermediate transfer belt was performed not by using the volume resistivity and the surface resistivity but by a different way. The resistance of the intermediate transfer belt 8 measured according to the different determination is the circumferential electrical resistance of the intermediate transfer belt.
Method of Determining Circumferential Resistance of Intermediate Transfer Belt
In the first embodiment, the resistance of the low-resistant belt is measured by a method illustrated in
All the belts demonstrate a tendency to gradually lower the resistance as the applied voltage is increased. This is characteristic of belts formed by dispersing carbon in resin.
The structure of
With the method shown in
In the image forming apparatus shown in
In
As shown in
Next, the potential of the belt surface of the intermediate transfer belt 8 that has a circumferential resistance of 104 to 108Ω will be described.
The surface voltmeter 37a and a measurement probe 38a are used to measure the potential of the first transfer roller 5aM (metal roller) of the image forming part 1a. Here, a surface voltmeter of MODEL 344 produced by Trek Japan KK is used for the measurement. The potential of the inner surface of the intermediate transfer belt may be determined with this method because the metal roller has the same potential as that of the inner surface of the intermediate transfer belt. In the same manner, the surface voltmeter 37d and a measurement probe 38d are used to measure the potential of the first transfer roller 5dM (metal roller) of the image forming part 1d, and thus the potential of the inner surface of the intermediate transfer belt is determined.
The surface voltmeter 37e and a measurement probe 38e are opposite a driving roller 11M and are used to measure the potential of the outer surface of the intermediate transfer belt. The surface voltmeter 37f and a measurement probe 38f are opposite the tension roller 13 and are used to measure the potential of the outer surface of the intermediate transfer belt. The driving roller 11M, the opposing roller for second transfer 12, and the tension roller 13 are respectively connected to electrical resistors Re, Rg, and Rf.
After measurement of the potential of the intermediate transfer belt by this measurement method, it is found that there is almost no potential difference between the different measurement positions and thus the intermediate transfer belt has an almost uniform belt potential. Thus, the belt used in the first embodiment can be said to have a conductivity although it has a certain level of resistance.
In the same manner,
In each of Belts A to E, the potential of the belt surface rises as the applied voltage becomes higher, while the potential of the belt surface decreases as the resistance is lowered in the order of 1 GΩ, 100 MΩ, and 10 MΩ. Herein, the resistors Re, Rf, and Rg are set to have the same resistance. If, however, the resistance of one of the resistors is lowered, the potential of the belt surface is lowered in accordance with the lowered resistance.
The above method cannot be used for measuring the potential of the belt surface of an intermediate transfer belt that has such a resistance that the current is not allowed to flow in the circumferential direction, such as the comparative belt. In addition, the measurement probes cannot be disposed in the structure, as shown in
Referring now to
As described above, the first transfer of toner is affected by the quantity of charge in the toner and the potential difference between the photosensitive drum and the intermediate transfer belt. Thus, the potential of the intermediate transfer belt has to be a predetermined value or larger so that the intermediate transfer belt maintains a favorable first transfer performance of the transfer unit.
With the above conditions that are required for the first embodiment taken into consideration, it is found that the potential of the intermediate transfer belt that is required to first-transfer the toner developed on the photosensitive drum is 200 V or larger.
At this time, the image forming parts 1a, 1b, 1c, and 1d have the same potential difference between the intermediate transfer belt and the corresponding photosensitive drums. Specifically, the first transfer portions of the image forming parts 1a, 1b, 1c, and 1d each have a potential difference of 300 V, that is the difference between the potential of −100 V of each photosensitive drum and the potential of +200 V of the intermediate transfer belt. This potential difference is required for the multilayer transfer of toners of three colors (the amount of toner is 300%, provided that the amount for solid printing of a single color is denoted by 100%), and is almost equivalent to that in the known structure for first transfers in which each first transfer roller is applied with a first transfer bias. Although image forming apparatuses usually have four colors, they do not usually form an image containing toners in an amount of 400%. Thus, as long as the maximum amount of toner is set to be within 210 to 280%, the image forming apparatuses sufficiently form full-color images.
As described above, in the first embodiment, a first transfer is performed by allowing a current to flow in the circumferential direction of the intermediate transfer belt so that the surface potential of the intermediate transfer belt is a predetermined potential. In other words, the transfer power source 19 causes a current to flow from the second transfer roller 15 to the multiple photosensitive drums via the intermediate transfer belt, and thus a first transfer is performed. In the first embodiment, a single transfer power source enables a first transfer and a second transfer by applying a voltage to the second transfer roller 15, which is a second transfer component. A second transfer involves transferring toner that has been first-transferred to the intermediate transfer belt 8, to a transfer medium by Coulomb force as in the case of a first transfer. Under the conditions according to the first embodiment, if wood-free paper (a basis weight of 75 g/m2) is used for a transfer medium, the voltage required for the second transfer is 2 kV or higher.
If the first transfer portions are separated from the second transfer unit by a distance that is large enough, an optimum transfer voltage for a first transfer may be applied to the second transfer roller 15 in the first transfer, if needed. Then, at the timing when a second transfer is to be performed after the first transfer is complete, the voltage may be switched to an optimum transfer voltage for the second transfer.
A voltage may be applied from the transfer power source 19 to the opposing roller for second transfer 12, instead of to the second transfer roller 15. In this case, the opposing roller for second transfer 12 serves as a current supply member. At the timing when a second transfer is to be performed after the first transfer is complete, the second transfer is performed if a voltage with a polarity that is the same as a polarity with which the toner is normally charged is applied from the transfer power source 19 to the opposing roller for second transfer 12.
A residual toner remaining on the intermediate transfer belt 8 is transferred to each photosensitive drum 2, and recovered from the photosensitive drum 2 by the corresponding drum cleaning device 6. A detailed description will be given with reference to
A residual toner that has not been transferred to a transfer medium in a second transfer is charged by a cleaning brush 71, which serves as a toner charging portion, of the cleaning unit 75. Since a voltage with a polarity that is opposite to a polarity with which the toner is normally charged is applied to the cleaning brush 71 from the cleaning power source 72, the residual toner is charged with a polarity that is opposite to a polarity with which the toner is normally charged. The charged residual toner is transferred to the photosensitive drum 2 in the first transfer portion. The toner that has been transferred to the photosensitive drum 1a is recovered by the drum cleaning device 6a.
In a case of consecutively forming images, while a residual toner is transferred from the intermediate transfer belt to each photosensitive drum, a subsequent toner image is concurrently first-transferred from each photosensitive drum to the intermediate transfer belt 8. In the first embodiment, the toner in the developing unit 4a is charged with a negative polarity, which is opposite to the polarity of the residual toner that has completely passed through the cleaning brush 71.
In the first embodiment, when the residual toner is transferred from the intermediate transfer belt to each photosensitive drum, a voltage is applied to the second transfer roller 15 so that the potential of the intermediate transfer belt is changed to be positive (so that the potential of the intermediate transfer belt has a polarity that is opposite to the polarity with which toner is normally charged).
In addition, a positive voltage is also applied to the cleaning brush 71 so that the residual toner is positively charged. Thus, a current flows in the circumferential direction of the intermediate transfer belt 8 from the cleaning brush 71 that is applied with the voltage.
As shown in
An increase in amount of current that flows in the circumferential direction of the intermediate transfer belt 8 causes the potential of the intermediate transfer belt 8 to rise accordingly. As described above, the first and second transfer performance of the transfer unit is maintained by regulating the surface potential of the intermediate transfer belt 8 to be 200 V. For this reason, if the potential cannot be maintained at 200 V, the first transfer portion may have a lower efficiency in the first transfer and the residual toner transfer. In addition, if the surface potential becomes greater than or equal to a desired potential, the efficiency with which a toner image from the intermediate transfer belt 8 is second-transferred to a transfer medium is lowered.
The comparative belt used in the image forming apparatus illustrated in
To solve the above problem, the voltages that are output from the transfer power source 19 and the cleaning power source 72 may be regulated in such a manner that the surface potential of the intermediate transfer belt 8 does not exceed 200 V. In this case, however, complex voltage regulation is required.
In the first embodiment, to prevent the first and second transfer performance of the transfer unit from being degraded, the resistors Rg, Re, and Rf that are connected to the multiple support rollers are used instead of resistance elements, to serve as constant-voltage elements that have a predetermined voltage threshold. Specifically, the support rollers are grounded via zener diodes or varistors, which serve as constant-voltage elements.
The situation is different, however, in the case where zener diodes or varistors are connected to the support rollers. Once the potential of the intermediate transfer belt exceeds a zener potential or a varistor potential, the current starts flowing to the support rollers. Thus, the potential of the intermediate transfer belt 8 is kept at the zener potential or the varistor potential. For this reason, the belt potential is prevented from exceeding the zener potential or the varistor potential even when an increasingly high voltage is applied. Thus, the belt potential is maintained at a constant value and thus the first transfer performance of the transfer unit can be made stable.
Considering the environmental effects, the zener potential or the varistor potential is set at a predetermined potential of 200 V. With this setting, the first and second transfer performance of the transfer unit can be made stable. At the same time, the voltage to be applied to the second transfer roller 15 and the voltage to be applied to the cleaning brush 71 can be optimized independently of each other.
Supplying a current from the current supply member in the rotational direction of the intermediate transfer belt eliminates the need for providing the multiple first transfer portions with the voltage sources. Even in the case where the toner-charging member supplies a current to the intermediate transfer belt, the potential of the intermediate transfer belt can be maintained at a predetermined potential by the constant-voltage elements connected to the support rollers.
Although a brush is employed as the charging member in the first embodiment, the present invention is not limited to this. A roller may be employed instead, as long as the roller allows a residual toner to be charged with a desired polarity. Alternatively, a combination of a brush and a roller may be employed.
The intermediate transfer belt according to the first embodiment is formed by adding carbon into PPS so as to be conductive, but the intermediate transfer belt is not limited to this. Other resins or metals may bring about effects that are similar to those of the first embodiment as long as the resins or metals have an equivalent conductivity. The intermediate transfer belt according to the first embodiment has a single layer or two layers. However, an intermediate transfer belt that has three layers or more, including an elastic layer or the like, may bring about similar effects as long as the intermediate transfer belt has the circumferential resistance described above.
The intermediate transfer belt having two layers is produced by forming the base layer and then forming the surface coat layer that coats the surface of the base layer. However, the method of producing the intermediate transfer belt is not limited to this and the intermediate transfer belt may be, for example, formed integrally, as long as the resistance satisfies the above conditions.
The current supply member may be a member other than the second transfer roller 15 and may be a member that comes into contact with the intermediate transfer belt 8.
In the first embodiment, a structure is described that prevents the surface potential of the intermediate transfer belt 8 from rising due to an excessive increase in the amount of current that flows in the circumferential direction of the intermediate transfer belt 8. The second embodiment, on the other hand, is made to solve problems that would possibly occur when the surface potential of the intermediate transfer belt 8 is lowered.
In the image forming apparatus, if a first transfer of an n-th image and a second transfer of an (n−1)-th image are concurrently performed as in the case of consecutively forming images, the surface potential of the intermediate transfer belt 8 may be lowered. If the surface potential of the intermediate transfer belt 8 is greatly lowered, the first and second transfer performance of the transfer unit may be degraded.
In the second embodiment, a structure is described in which the potential of the belt surface of the intermediate transfer belt 8 is maintained while a transfer medium is passing through the second transfer unit. Note that components and structures described in the first embodiment are not described herein, such as the structure of the image forming apparatus.
When a transfer medium P is passing through the second transfer unit in which the second transfer roller 15 is used as the current supply member, the potential of the intermediate transfer belt 8 may fail to be maintained at a predetermined value. This is because the amount of current supplied from the current supply member to the intermediate transfer belt 8 decreases with the presence of the high-resistance transfer medium P. With the decrease in amount of current, the surface potential of the intermediate transfer belt 8 may be lowered and the performance of each first transfer portion in the case of first transfers of toner may be degraded.
In
In the second embodiment, the voltage to be applied to the cleaning brush 71 of the toner charging unit 75 is regulated so that the potential of the intermediate transfer belt 8 is maintained at 200 V even when a transfer medium P is passing through the second transfer unit.
In Step S1, a user's operation is input, and thus an image-forming-operation start signal is input to a main body of the image forming apparatus 100 from a host apparatus (not illustrated) such as a PC or the like, together with transfer medium information including the size and a suitable print mode of a transfer medium, and the number of transfer media to be printed. In this embodiment, the transfer medium information is input from a host apparatus (not illustrated) such as PC. The present invention is not limited to this, however. A media sensor that serves as a sensing member may be disposed in the main body of the image forming apparatus 100 and the transfer medium information may be sensed by the media sensor.
In Step S2, the transfer medium information and the like that are input into the main body of the image forming apparatus 100 are stored in a memory (not illustrated). In Step S3, environmental information is transmitted from an environment sensor (not illustrated) that is disposed in the main body of the image forming apparatus 100 and that serves as an environment sensing member, and is then stored in the memory.
In Step S4, a target potential of the intermediate transfer belt 8, at which a first transfer is favorably performed under the current environmental conditions, is derived from an intermediate-transfer-belt target potential table on the basis of the environmental information stored in the memory. The derived target potential is then stored in the memory. The intermediate-transfer-belt target potential table stores in advance target potentials of the intermediate transfer belt 8 at which a first transfer is favorably performed under many different sets of environmental conditions. The target potentials have been calculated using an image forming apparatus that is similar to the image forming apparatus 100 according to this embodiment.
In Step S5, a second-transfer voltage at which a second transfer is favorably performed under the current image forming conditions is derived from a second-transfer voltage table on the basis of the transfer medium information, the environmental information, and the target potential of the intermediate transfer belt 8, which have been stored in the memory. The derived second-transfer voltage is then stored in the memory. The second-transfer voltage table stores in advance second-transfer voltages at which a second transfer is favorably performed on the basis of the transfer medium information, the environment information, and the target potential of the intermediate transfer belt 8, which have been calculated using an image forming apparatus that is similar to the image forming apparatus 100 according to this embodiment.
In Step S6, cleaning voltages (compensation voltages) that are applied from the cleaning power source 72 to the cleaning brush 71 are determined for cases where a transfer medium P is passing through the second transfer unit (for a sheet-feeding period) and where no transfer media P is passing through the second transfer unit (for a non-sheet-feeding period). The voltages that are applied to the cleaning brush 71 are derived from a compensation voltage table on the basis of the second-transfer voltage, the target potential of the intermediate transfer belt 8, and the transfer medium information, which have been stored in the memory. The compensation voltage table stores in advance voltages at which a first transfer and cleaning are favorably performed under different sets of conditions including the second-transfer voltage, the target potential of the intermediate transfer belt 8, and the transfer medium information, which are calculated using an image forming apparatus that is similar to the image forming apparatus 100 according to this embodiment. In Step S7, an image forming operation is started.
When the image forming operation is started, a controlling unit 101 sets the cleaning voltage that is to be applied to the cleaning brush 71 to a value for the non-sheet-feeding period.
At the timing when a transfer medium P arrives at the second transfer unit, the cleaning voltage is switched to the compensation voltage for the sheet-feeding period. After the transfer medium P has completely passed through the second transfer unit, the voltage is switched back to the cleaning voltage for the non-sheet-feeding period. Specifically, a first voltage that is applied from the cleaning power source 72 to the cleaning brush 71 while a transfer medium P is passing through the second transfer unit (during the sheet-feeding period) is set to be larger than a second voltage that is applied from the cleaning power source 72 to the cleaning brush 71 before a transfer medium P arrives at the second transfer unit (during the non-sheet-feeding period). The first voltage and the second voltage are determined in Steps S4 and S5.
Consequently, as illustrated in
As described above, according to the embodiment of the present invention, the cleaning voltage that is applied to the cleaning brush 71 during the sheet-feeding period and the non-sheet-feeding period is regulated in accordance with the second-transfer voltage, the target potential of the intermediate transfer belt 8, and the transfer medium information. By regulating the cleaning voltage, the potential of the intermediate transfer belt 8 is less likely lowered, and thus the performance of each first transfer portion in the case of first transfers of toner is prevented from being degraded.
In this embodiment, a photosensitive drum and toner which are normally charged with a negative polarity are used. The present invention, however, is not limited to this. A photosensitive drum and toner which are normally charged with a positive polarity may be used. In this case, the polarity of voltages to be applied to components including the charging rollers 3a, 3b, 3c, and 3d and the developing units 4a, 4b, 4c, and 4d is changed according to needs.
The above-described regulation may be performed only when a high-resistance transfer medium is used. With a low-resistance transfer medium, such as a transfer medium in hot and humid surroundings, that the degree to which supply current is decreased by the resistance of the transfer medium is small. In this case, the first voltage that is applied from the charging power source 72 to the cleaning brush 71 when a transfer medium is passing through the second transfer unit (during the sheet-feeding period) may be set to the same value as the second voltage that is applied from the charging power source 72 to the cleaning brush 71 before a transfer medium arrives at the second transfer roller (during the non-sheet-feeding period).
Although the cleaning brush 71 is used as the charging member in this embodiment, the present invention is not limited to this. Rollers or other components may be used instead, as long as the rollers and the other components allow toner to be charged with a predetermined polarity. Furthermore, the charging member may be formed of multiple components by, for example, combining a brush member and a roller member.
With the use of the electrically conductive belt according to this embodiment, the potential of the belt surface of the intermediate transfer belt 8 for the cases where a transfer medium is and is not passing through the second transfer unit is maintained by regulating the voltage to be applied to the charging member.
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. 2010-283772, filed Dec. 20, 2010, and Japanese Patent Application No. 2011-161868, filed Jul. 25, 2011, which are hereby incorporated by reference herein in their entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2010-283772 | Dec 2010 | JP | national |
| 2011-161868 | Jul 2011 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2011/079120 | 12/9/2011 | WO | 00 | 5/19/2014 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2012/086525 | 6/28/2012 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 5978638 | Tanaka et al. | Nov 1999 | A |
| 9052677 | Horiguchi et al. | Jun 2015 | B2 |
| Number | Date | Country |
|---|---|---|
| 10-268667 | Oct 1998 | JP |
| 2001-125338 | May 2001 | JP |
| 2001-175092 | Jun 2001 | JP |
| 2003-35986 | Feb 2003 | JP |
| 2005-250254 | Sep 2005 | JP |
| 2006-259640 | Sep 2006 | JP |
| 2009-205012 | Sep 2009 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20140321891 A1 | Oct 2014 | US |
