1. Field of the Invention
The present invention relates to an image forming device in which a photoconductive drum is charged by a corona discharge method. In particular, the present invention relates to an image forming device which optimizes the photoconductive drum and a peripheral system of the photoconductive drum at a start of a print job by carrying out a pre-rotation process.
2. Description of the Related Art
Many copy machines and facsimile machines or the like function as an image forming device which forms an image on printing paper according to image data scanned from an original document or image data received by facsimile. In the image forming device, light is irradiated on a uniformly charged photoconductive drum according to the image data to be printed, and an electrostatic latent image is formed. Toner is supplied onto the electrostatic latent image, and the electrostatic latent image is formed into a toner image. Then, the toner image is transferred onto the printing paper. As one charging method of the photoconductive drum, a corona discharge method has been conventionally used. The corona discharge method is a non-contact charging method. Under the corona discharge method, a high voltage is applied to a tungsten corona wire or the like. Accordingly, a corona discharge generates between the corona wire and the photoconductive drum. When the corona is being discharged, ions generated as a result of ionization of the surrounding air are guided towards the photoconductive drum. As a result, the surface of the photoconductive drum is charged.
In the image forming device using the corona discharge method, when the corona is being discharged, discharge product gases such as NOx and O3 are generated. There exists a problem that a normal image forming process is inhibited by the discharge product gases. For example, NOx combines with moisture in the air to form HNO2. When HNO2 adheres onto the photoconductive drum, HNO2 melts the surface of the photoconductive drum to make the surface uneven. As a result, the charging of the surface of the photoconductive drum is inhibited. Additionally, O3 prevents a movement of the charge on the photoconductive drum. As a result, a formation of an electrostatic latent image is blocked. Therefore, a fan or the like is arranged in the image forming device to discharge the corona product gases to the outside of the image forming device. However, when the discharge product gases are not completely discharged and remain inside the image forming device, the discharge product gases pollute the surface of the photoconductive drum. Accordingly, during a pre-rotation process carried out at a start of a print job, the polluted surface of the photoconductive drum is required to be refreshed. The pre-rotation process is a process for adjusting the photoconductive drum and the peripheral system of the photoconductive drum into an optimum state by securing a given period of time at the start of the print job in order to enable a normal image forming process. During the pre-rotation process, for example, since a cleaning blade makes contact with the photoconductive drum, the polluted surface of the photoconductive drum is abraded and a new surface is exposed.
The period of time required for the pre-rotation process changes according to a surrounding environmental condition. Therefore, a conventionally proposed method provides a temperature sensor for measuring an outside air temperature and optimizes a pre-rotation period according to this measurement result.
However, in the above-described conventional image forming device, no consideration is made regarding an aspect that a level of pollution of the photoconductive drum changes according to a period from a completion of a previous print job until a start of a next print job. That is, when the image forming device is left for a long period of time without a print job being executed, for example, from an end of a week until a beginning of the next week, the level of the pollution on the surface of the photoconductive drum caused by the discharge product gases is high. Meanwhile, when a next print job is started immediately after a completion of a previous print job, the level of the pollution on the surface of the photoconductive drum is low. However, in the conventional image forming device, an execution period of the pre-rotation process is constant regardless of a job interval. Therefore, when the image forming device is left for a long period of time and the level of the pollution of the photoconductive drum is high, a normal image forming process cannot be carried out due to insufficient cleaning. Meanwhile, when the image forming device is left for a short period of time and the level of the pollution of the photoconductive drum is low, the pre-rotation process is carried out over an unnecessarily long period of time. As a result, the start of the next print job is delayed.
In order to overcome the problems described above, according to preferred embodiments of the present invention, in an image forming device which charges a photoconductive drum by a corona discharge method, regardless of an elapse of time from the completion of a previous print job, the photoconductive drum polluted by discharge product gases is reliably refreshed during a pre-rotation process carried out at a start of the print job. Therefore, a satisfactory image quality can be obtained from a first sheet of the print job.
According to a preferred embodiment of the present invention, an image forming device includes a motor, a photoconductive drum, a charging unit, and an abrasion tool. The photoconductive drum is driven and rotated by the motor, and a photoconductive layer is formed on a surface of the photoconductive drum. The charging unit is arranged at a periphery of the photoconductive drum and charges the photoconductive drum by the corona discharge method. The abrasion tool abrades the surface of the photoconductive drum while the photoconductive drum is rotating. After the motor is driven and a print job is started, a pre-rotation process is executed over a predetermined period of time. Further, the pre-rotation process is a process for adjusting the photoconductive drum and a peripheral system of the photoconductive drum into an optimum state. In such an image forming device, a job interval is measured from when the motor is stopped to end the previous print job until when the motor is driven to start the next print job. According to the measured job interval, an execution period of the pre-rotation process for the next print job is calculated.
According to the above-described image forming device, the execution period of the pre-rotation process is calculated according to the job interval. Therefore, the pre-rotation process can be executed for the optimum execution period according to the level of the pollution on the photoconductive drum. Accordingly, it is possible to prevent insufficient refreshing of the photoconductive drum when the level of the pollution is high. In addition, since the pre-rotation process is not carried out over an unnecessarily long period of time when the level of the pollution is low, it is possible to prevent a delay in the start of the next print job.
In the image forming device, a first sheet of the printing paper is preferably fed in synchronism with an end of the pre-rotation process.
According to such a preferred embodiment, the first sheet of the printing paper is fed at the same time as the end of the pre-rotation process. Therefore, it is possible to shorten a period of time required from when a print job execution command is issued until when the print job is completed.
The image forming device further includes a fixing unit which heats and fixes a toner image transferred onto the printing paper from the photoconductive drum. In this case, the execution period of the pre-rotation process for the next print job is preferably a theoretical value of an execution period calculated based on the job interval or a period of time required from when the next print job is started until when the fixing unit reaches a predetermined paper feed starting temperature, whichever is longer.
According to such a preferred embodiment, even when the theoretical value of the execution period of the pre-rotation process is small, a minimum required execution period is secured such that a fixing unit temperature reaches a temperature necessary for fixing the toner image when the printing paper passes through the fixing unit. As a result, it is possible to prevent insufficient fixing by the fixing unit.
The image forming device also includes an environmental condition sensor which detects an environmental condition near the photoconductive drum. In this case, the execution period of the pre-rotation process for the next print job is preferably corrected according to a detection result of the environmental condition sensor.
According to such a preferred embodiment, the execution period of the pre-rotation process is corrected according to the environmental condition. Therefore, the execution period of the pre-rotation process can take an even more optimum value according to the level of the pollution on the photoconductive drum.
Other features, elements, processes, steps, characteristics and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the present invention with reference to the attached drawings.
A description will be made of an image forming device according to preferred embodiments of the present invention with reference to the drawings. The image forming device is preferably a copy-and-facsimile Multi Function Peripheral (MFP) including a copying function for copying an original document, a facsimile communication function, and an Internet facsimile communication function, or the like. The copy-and-facsimile MFP forms an image on printing paper in accordance with image data scanned from the original document or image data received by facsimile. The present invention is not limited to the copy-and-facsimile MFP. For example, the present invention is applicable to a copying machine including only a copying function or a facsimile machine including only a facsimile communication function, or any other suitable machine.
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In the above-described image forming device 1, when a user issues a print job execution command, after a print job is started, first, a pre-rotation process is carried out. Under the pre-rotation process, the photoconductive drum 6 and the peripheral system of the photoconductive drum 6 are adjusted into an optimum state. The peripheral system of the photoconductive drum 6 includes, for example, the charging unit 7, the developing unit 9, and the transfer roller 10, or any other device that works in conjunction with the photoconductive drum 6. At the same time as a completion of the pre-rotation process, the printing papers P accommodated in the paper feed cassette 2 are fed into the transportation path 3, and an image forming process is carried out. A description will be made of the image forming process for one printing paper P. After the pre-rotation process has been completed, first, the surface of the photoconductive drum 6 is uniformly charged by the charging unit 7. The exposing unit 8 irradiates light according to the image data to be printed. Accordingly, an electric charge on the photoconductive drum 6 is partially removed, and an electrostatic latent image is formed. The developing unit 9 supplies the toner to the electrostatic latent image, and as a result, a toner image is formed. Meanwhile, in synchronism with the completion of the pre-rotation process, the printing papers P accommodated in the paper feed cassette 2 are picked up one sheet at a time from an uppermost sheet by the pickup roller 4. The picked-up printing paper P is fed into the transportation path 3. The printing paper P is pressed against the photoconductive drum 6 by the transfer roller 10 at a transfer nip position 25. Accordingly, the toner image formed on the photoconductive drum 6 is transferred onto the printing paper P. Furthermore, the printing paper P is transported downstream along the transportation path 3. When the printing paper P is heated and pressed by the fixing unit 13, the toner image on the printing paper P is fixed. Then, the printing paper P is output onto a paper output tray (not illustrated). Meanwhile, after the toner image has been transferred, the charge eliminating lamp 11 eliminates the electric charge from the surface of the photoconductive drum 6. The cleaning blade 12 removes the toner and the paper dust or the like remaining on the surface of the photoconductive drum 6. Then, the surface of the photoconductive drum 6 is charged again by the charging unit 7.
Next, a detailed description will be made of the pre-rotation process.
After a prescribed period of time elapses from the time T0, i.e., at time T1, when the user issues a print job execution command, the printer controller 19 switches on the heater 20 of the fixing unit 13. As a result, as illustrated in
Next, a description will be made of a method for calculating the pre-rotation period F(t), i.e., a method for calculating the time T3 when the pre-rotation process ends. First, the printer controller 19 calculates the theoretical value of the pre-rotation period F(t) by using a prescribed calculation formula in accordance with the job interval t. The printer controller 19 adds the theoretical value of the pre-rotation period F(t) to the time T2 to calculate the theoretical value of the ending time T3. That is, the pre-rotation period F(t) changes according to the job interval t. Therefore, according to the level of the pollution on the photoconductive drum 6 resulting from the discharge product gases, an abrasion period of the photoconductive drum 6 by the cleaning blade 12 becomes an optimum length. That is, when the image forming device 1 is left for a long period of time without any print job being carried out, for example, from an end of a week until a beginning of the next week, the level of the pollution on the photoconductive drum 6 resulting from the discharge product gases is high. Therefore, the pre-rotation period F(t) is lengthened, and the abrasion period by the cleaning blade 12 also becomes long. As a result, the surface of the photoconductive drum 6 is even more reliably refreshed. Meanwhile, when a next print job is started immediately after a completion of a previous print job, the level of the pollution on the photoconductive drum 6 by the discharge product gases is low. As a result, the pre-rotation period F(t) is shortened, and the abrasion period by the cleaning blade 12 also becomes short. Accordingly, the surface of the photoconductive drum 6 is reliably refreshed without a delay in the start of the next print job. Further, as a computation formula for calculating the pre-rotation period F(t) from the job interval t, for example, it is possible to use a linear function illustrated in
Next, in accordance with the temperature gradient, the printer controller 19 calculates a time when the fixing unit temperature, which was Temp 1 at time T2, reaches a predetermined paper feed starting temperature Temp 2. The printer controller 19 compares the time when the fixing unit temperature reaches the paper feed starting temperature Temp 2 with the theoretical value of the ending time T2 calculated as described above. Then, the printer controller 19 selects a time whichever is later. A condition of the fixing unit temperature is added to the theoretical value of the pre-rotation period F(t) as described above. This is because when the theoretical value of the pre-rotation period F(t) is small, the paper feeding is started before the fixing unit temperature increases sufficiently, and the fixing may be insufficient as a result of the fixing unit temperature not reaching the temperature necessary for fixing when the printing paper P passes through the fixing unit 13. In order to solve such a problem, a minimum required fixing unit temperature at time T2 is provided as a condition such that the fixing unit temperature has reached the temperature necessary for fixing when the printing paper P passes through the fixing unit 13.
Lastly, the printer controller 19 detects the environmental condition from the environmental condition sensor 15. The printer controller 19 corrects the later time selected as described above in accordance with the detection result. The printer controller 19 calculates the corrected time as the ending time T3 of the pre-rotation process. As described above, since the correction is carried out in accordance with the detection result of the environmental condition sensor 15, an even more optimum ending time T3 can be calculated by considering a change in the level of the pollution on the photoconductive drum 6 resulting from a difference in the environmental condition.
Further, in the present preferred embodiment, the pre-rotation period F(t) is calculated by adding the temperature condition of the fixing unit 13 to the theoretical value of the pre-rotation period F(t). Alternatively, the rotation starting temperature Temp 1 at time T2 may be calculated such that the fixing unit 13 reaches the temperature necessary for the fixing when the printing paper P passes through the fixing unit 13. Accordingly, without adding the condition of the fixing unit temperature, the theoretical value of the pre-rotation period F(t) can be directly provided as the pre-rotation period F(t).
As illustrated in
Further, in the present preferred embodiment, the cleaning blade 12 is used as an abrasion tool for abrading and refreshing the polluted photoconductive drum 6. In place of the cleaning blade 12, in a system without a cleaning blade 12, in the case of the image forming device 1 using a one-component developing method, the photoconductive drum 6 may be abraded by scraping the photoconductive drum 6 with toner. In the case of the image forming device 1 using a two-component developing method, the photoconductive drum 6 may be abraded by scraping the photoconductive drum 6 by a carrier defining the two-component developer.
While the present invention has been described with respect to preferred embodiments thereof, it will be apparent to those skilled in the art that the disclosed invention may be modified in numerous ways and may assume many embodiments other than those specifically set out and described above. Accordingly, it is intended by the appended claims to cover all modifications of the present invention that fall within the true spirit and scope of the present invention.
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