This patent application is based on and claims priority pursuant to 35 U.S.C. § 119(a) to Japanese Patent Application No. 2017-110794, filed on Jun. 5, 2017, in the Japan Patent Office, the entire disclosure of which is hereby incorporated by reference herein.
Technical Field
Aspects of the present disclosure relate to a powder-amount detection device and an image forming apparatus to detect the amount of powder in a powder container.
Related Art
Typically, an electrophotographic image forming apparatus includes a replaceable toner bottle to replenish toner for image formation. To reduce the user's downtime caused by the replacement of toner bottles, various devices have been proposed to detect the amount of toner in the toner bottle and grasp the bottle replacement timing beforehand.
In an aspect of the present disclosure, there is provided a powder-amount detection device that includes an outer electrode, an inner electrode, and a detector. The outer electrode is disposed outside a powder container to be replaceably installed to an image forming apparatus. The inner electrode is disposed inside a powder supply port of the powder container. The detector is configured to apply an electric field between the outer electrode and the inner electrode to detect a capacitance between the outer electrode and the inner electrode.
In another aspect of the present disclosure, there is provided an image forming apparatus that includes an electrophotographic image forming unit, a powder container housing to house the powder container to supply powder to the electrophotographic image forming unit, and the powder-amount detection device disposed in the powder container housing.
A more complete appreciation of the disclosure and many of the attendant advantages and features thereof can be readily obtained and understood from the following detailed description with reference to the accompanying drawings, wherein:
The accompanying drawings are intended to depict embodiments of the present disclosure and should not be interpreted to limit the scope thereof. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.
In describing embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that have a similar function, operate in a similar manner, and achieve a similar result.
Hereinafter, a powder-amount detection device according to an embodiment of the present disclosure and an image forming apparatus including the powder-amount detection device are described with reference to the drawings.
Image Forming Apparatus.
First, the overall configuration of the image forming apparatus according to an embodiment of the present disclosure is described below. An image forming apparatus 100 illustrated in
In a middle of an image forming apparatus body of the image forming apparatus 100, four image forming units 4Y, 4M, 4C, and 4K are disposed. The image forming units 4Y, 4M, 4C, and 4K have the same configuration except for accommodating developers of different colors of yellow (Y), magenta (M), cyan (C), and black (K) corresponding to color separation components of a color image.
For example, each of the image forming units 4Y, 4M, 4C, and 4K includes a drum-shaped photoconductor 5 as a latent image bearer, a charging device 6 to charge a surface of the photoconductor 5, a developing device 7 to supply toner as powder, and a cleaning device 8 to clean the surface of the photoconductor 5.
In
The exposure device 9 to expose the surface of each photoconductor 5 is disposed below each of the image forming units 4Y, 4M, 4C, and 4K. The exposure device 9 includes, e.g., a laser light source, a polygon mirror, an f-θ lens, a plurality of reflection mirrors and irradiates the surface of each photoconductor 5 with a laser beam according to image data, thus forming an electrostatic latent image on the surface of each photoconductor 5.
The transfer device 3 is disposed above each of the image forming units 4Y, 4M, 4C, and 4K. The transfer device 3 includes an intermediate transfer belt 30 as an intermediate transfer member, four primary transfer rollers 31 as primary transfer members, a secondary transfer roller 36 as a secondary transfer member, a secondary transfer backup roller 32, a cleaning backup roller 33, a tension roller 34, and a belt cleaning device 35.
The intermediate transfer belt 30 is an endless belt, and is stretched taut by the secondary transfer backup roller 32, the cleaning backup roller 33, and the tension roller 34. Here, as the secondary transfer backup roller 32 is driven to rotate, the intermediate transfer belt 30 circulates (rotates) in a direction indicated by arrow RD in
Each of the four primary transfer rollers 31 sandwiches the intermediate transfer belt 30 with each photoconductor 5, to form a primary transfer nip. A power supply is connected to each of the primary transfer rollers 31 so that a predetermined direct current (DC) voltage or a predetermined alternating current (AC) voltage is applied to each primary transfer roller 31.
The secondary transfer roller 36 sandwiches the intermediate transfer belt 30 with the secondary transfer backup roller 32, to form a secondary transfer nip. Similarly with the primary transfer roller 31, a power supply is also connected to the secondary transfer roller 36 so that a predetermined DC voltage or AC voltage is applied to the secondary transfer roller 36.
The belt cleaning device 35 includes a cleaning brush and a cleaning blade that are disposed so as to contact the intermediate transfer belt 30. Waste toner collected by the belt cleaning device 35 is accommodated in a waste toner container via a waste toner drain tube.
At an upper part of the image forming apparatus body, a bottle housing 200 is disposed. In the bottle housing 200, four toner bottles 210Y, 210M, 210C, and 210K as powder containers to store replenishment toner are replaceably mounted. Toner as powder is supplied from each of the toner bottles 210Y, 210M, 210C, and 210K to each developing device 7 via a replenishment path disposed between each of the toner bottles 210Y, 210M, 210C, 210K and each developing device 7. At outlet portions of the toner bottles 210Y, 210M, 210C, and 210K, a toner-amount detection device 250 as a powder-amount detection device is disposed. The toner-amount detection device 250 is described later with reference to
On the other hand, at a lower part of the image forming apparatus body of the image forming apparatus 100, the sheet feeding section B is disposed. The sheet feeding section B includes, e.g., a sheet feed tray 10 to accommodate recording media P as sheet-shaped materials (recording media) and a sheet feed roller 11 to feed the recording media P from the sheet feed tray 10.
Examples of the recording media P include thick paper, postcards, envelopes, thin paper, coated paper (or art paper), tracing paper, and OHP sheets, in addition to plain paper. The image forming apparatus 100 may further include a bypass sheet feeding mechanism. In the present embodiment, “thick paper” means paper having a basis weight of 160 g/m2 or more.
In the image forming apparatus body, a conveyance path R to eject the recording medium P from the sheet feed tray 10 through the secondary transfer nip to the outside of the image forming apparatus 100. On the conveyance path R, a pair of registration rollers 12 as timing rollers to convey the recording medium P to the secondary transfer nip at proper conveyance timing is disposed at an upstream side from the position of the secondary transfer roller 36 in a conveyance direction of the recording medium P.
Further, on a downstream side from the position of the secondary transfer roller 36 in the conveyance direction of the recording medium P, the fixing device 20 is disposed that presses and heats the recording medium P bearing an unfixed toner image to fix the toner image on the recording medium P. A pair of sheet ejection rollers 13 to eject the recording medium P to the outside of the image forming apparatus 100 is disposed on the downstream side from the fixing device 20 in the conveyance direction of the recording medium P on the conveyance path R. The sheet ejection tray 14 to stock the recording medium P ejected outside the image forming apparatus 100 is disposed on an upper surface of the image forming apparatus body.
Basic Operation of Image Forming Apparatus.
Next, a basic operation of the image forming apparatus 100 according to the present embodiment is described. First, when image forming operation is started, each photoconductor 5 in each of the image forming units 4Y, 4M, 4C, and 4K is driven to rotate clockwise in
Here, image data to be exposed on each photoconductor 5 is monochromatic image data obtained by decomposing a full-color image into color data of yellow, magenta, cyan and black. As toner is supplied to the electrostatic latent image formed on each photoconductor 5 by each developing device 7, the electrostatic latent image is visualized as an image.
When the image forming operation is started, the secondary transfer backup roller 32 is driven to rotate counterclockwise in
Then, when the image of the corresponding color on each photoconductor 5 reaches the primary transfer nip with the rotation of each photoconductor 5, the image on each photoconductor 5 is sequentially transferred onto the intermediate transfer belt 30 in a superimposed manner by action of the transfer electric field formed at the primary transfer nip.
Thus, a full-color image is borne on the surface of the intermediate transfer belt 30. Toner on each photoconductor 5 that has not been transferred to the intermediate transfer belt 30 is removed by the cleaning device 8. The surface of each photoconductor 5 is neutralized by a neutralizing device, and the surface potential is initialized.
In a lower portion of the image forming apparatus 100, the sheet feed roller 11 starts to rotate, and the recording medium P is sent out from the sheet feed tray 10 to the conveyance path R. The conveyance of the recording medium P fed to the conveyance path R is temporarily stopped by the pair of registration rollers 12.
Then, the pair of registration roller 12 starts to rotate at a predetermined timing, and the recording medium P is conveyed to the secondary transfer nip at the timing when the images on the intermediate transfer belt 30 reaches the secondary transfer nip. At this time, the secondary transfer roller 36 is applied with a transfer voltage having the polarity opposite to the charging polarity of toner of the images on the intermediate transfer belt 30, thus forming a transfer electric field in the secondary transfer nip.
By the transfer electric field, the images on the intermediate transfer belt 30 are collectively transferred onto the recording medium P. Residual toner on the intermediate transfer belt 30 that has not been transferred to the recording medium P is removed by the belt cleaning device 35 and drained to the waste toner container.
Then, the recording medium P is conveyed to the fixing device 20, and the images on the recording medium P are fixed on the recording medium P by the fixing device 20. The recording medium P conveyed from the fixing device 20 passes through the curl correcting device 21 and is ejected onto the sheet ejection tray 14 outside the image forming apparatus body.
Although the above-described description is about the image forming operation performed when a full color image is formed on the recording medium P, the image forming apparatus 100 can form a single color image using any one of the four image forming units 4Y, 4M, 4C, and 4K or form images of two or three colors using any two or three of the image forming units 4Y, 4M, 4C, and 4K.
Toner-Amount Detection Device.
Next, the toner-amount detection device 250 to detect the amount of toner in the toner bottle 210 is described. As illustrated in
The axis of the toner supply port 210b is the same as the axis of the toner bottle 210, and the toner bottle 210 is rotationally symmetrical as a whole. A spiral rib or groove is formed on an inner circumferential surface of the toner bottle 210 so that toner T can be moved toward the toner supply port 210b by the rotation of the toner bottle 210.
The toner bottle 210 illustrated in
A cylindrical toner conveyance unit 212 as a powder conveyance unit is horizontally fixed and arranged coaxially with the horizontally-set toner bottle 210 on the back side of the bottle housing 200. The toner conveyance unit 212 includes a cylindrical guide portion 212a and a conveyance screw 212b. The conveyance screw 212b as a powder conveyor is rotatably housed in the cylindrical guide portion 212a and extends to a leading end portion of the cylindrical guide portion 212a. An upper wall of the leading end portion of the cylindrical guide portion 212a is cut out by a predetermined length in the axial direction to be a toner supply port 212c.
An inner electrode 216 is disposed on an outer circumferential surface of the cylindrical guide portion 212a of the toner conveyance unit 212. The inner electrode 216 can be formed by molding a sheet-shaped conductive metal into a cylindrical shape and adhering the molded metal to the outer circumferential surface of the cylindrical guide portion 212a. An outer electrode 215 is disposed on an outer periphery of the toner bottle 210 so as to be positioned radially outside the inner electrode 216.
The outer electrode 215 can also be formed by molding a sheet-shaped conductive metal into a cylindrical shape. The inner electrode 216 and the outer electrode 215 are parallel to the axis of the toner bottle 210 or the toner supply port 210b, so that the inner electrode 216 and the outer electrode 215 are also arranged coaxially and in parallel.
As illustrated in
The inter-electrode voltage measurement device 220 is connected to a remaining-amount determination device 230. The remaining-amount determination device 230 detects the amount of toner present between the inner electrode 216 and the outer electrode 215 from the magnitude of the capacitance between the inner electrode 216 and the outer electrode 215. The relationship between the magnitude of the capacitance and the toner amount can be obtained in advance by, e.g., experiments.
In
On the other hand, since there is no inner electrode at the portion of the toner supply port 212c, the outer electrode 215 may have a partially-cut-out shape in which a portion corresponding to the toner supply port 212c is partially cut out. For such a shape, the outer electrode 215 has a C-shaped cross section opened upward in
The above-described outer electrode 215 can be disposed on an apparatus body side as illustrated in
When the outer electrode 215 is fixedly disposed on the apparatus body side as illustrated in
If the outer electrode 215 is disposed on the toner bottle side as illustrated in
Further, even when the surface of the outer electrode 215 becomes dirty due to toner scattering or the like in the image forming apparatus, the outer electrode 215 can be replaced with replacement of the toner bottle 210. The connection between the outer electrode 215 and the inter-electrode voltage measurement device 220 can be secured by, for example, a contact point 220a at which the outer electrode 215 contacts the inter-electrode voltage measurement device 220 when the toner bottle 210 is installed.
As a method of attaching the outer electrode 215, for example, a method of integrally installing the outer electrode 215 on a display label, such as a part number to be affixed to the outer circumferential surface of the toner bottle 210, can be considered. Integrating the outer electrode 215 with the display label can omit the trouble of attaching the outer electrode 215.
Operation of Toner Amount Detection Device.
When the toner bottle 210 is inserted and set rightward in the bottle housing 200 in
That is, the toner T in the toner bottle 210 is gradually moved in the right direction in
As the toner T is conveyed to the outside of the toner bottle, the surface of the toner T in the toner bottle is lowered, and the remaining-amount determination device 230 detects a decrease in the amount of toner correspondingly. The inner electrode 216 is positioned on a leading end surface of the toner conveyance unit 212 on the apparatus body side and is inserted into the toner supply port 210b of the toner bottle 210 when the toner bottle 210 is installed to the bottle housing 200. Thus, the inner electrode 216 and the outer electrode 215 are arranged with the toner T sandwiched between the inner electrode 216 and the outer electrode 215. Such an electrode arrangement allows the toner amount to be accurately detected just before the toner runs out.
That is, when the amount of toner is large as illustrated in
Near the toner supply port 210b of the toner bottle 210, the toner T always stays until just before the toner amount becomes zero. That is, even when the amount of toner becomes small and the toner T is completely absent on the side of the bottom portion 210a of the toner bottle 210, as illustrated in
Therefore, the amount of toner can be accurately detected until just before the toner runs out, thus preventing the replacement timing of the toner bottle 210 from being too early or too late due to erroneous detection of the toner amount.
In
In
Although some embodiments of the present disclosure have been described above, the present invention is not limited to the above-described embodiments, and various variations and modifications are possible within the scope of the technical idea described in the claims. For example, although the shapes of the toner bottle 210, the outer electrode 215, and the inner electrode 216 are cylindrical in the above-described embodiment, the shapes of the toner bottle 210, the outer electrode 215, and the inner electrode 216 are not limited to such cylindrical shapes and may be any suitable shapes as long as the outer electrode 215 and the inner electrode 216 can be arranged as described in appended claim 1.
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