The present invention relates to a toner transport apparatus.
Image forming apparatuses which use an electrophotographic system to form images by forming toner images, such as printers, copiers, and facsimile machines, are equipped with developer supply apparatuses in developing apparatuses to supply developer which has been consumed by the formation of images. A developer supply apparatus stores, in a storage unit (a hopper), a certain amount of developer taken from a developer container, and operates a transport means to supply the developer to the developing apparatus from the storage unit at the required time.
Patent Literature 1 (Japanese Patent No. 5762052) proposes a configuration in which toner taken from a toner bottle, which is an example of a developer container, is held in a low-capacity hopper, and is transported to the developing apparatus at the required time using a screw-type transport mechanism. According to Patent Literature 1, it is necessary to continuously store and hold a constant amount of toner within a reservoir unit so that the screw-type transport mechanism can supply the toner in a stable manner. As such, a control unit in an image forming apparatus according to Patent Document 1 uses an optical sensor to detect the surface height of the toner within the storage unit, and on the basis of that information, controls the amount of toner resupplied to the storage unit from the toner bottle.
In Patent Document 1, toner is output to the storage unit from the toner bottle, which serves as a developer container, and the toner is then resupplied to the developing apparatus from the storage unit via a transport path. The remaining amount of toner is detected using an optical sensor which detects whether or not toner is present at a predetermined height within the storage unit. As such, the system will determine that there is toner left as long as toner remains in the storage unit, even if there is no more toner in the developer container. Thus even when the developer container is empty or near empty, it will take a certain amount of time for the system to determine that there is no toner remaining.
Having been achieved in light of the foregoing issue, an object of the present invention is to provide a technique for quickly determining that a developer container holding toner is empty or almost empty.
The present invention provides a toner transport apparatus comprising:
a storing portion configured to store toner used by a developing apparatus;
an ejection port for outputting the toner from the storing portion;
a transport path unit that includes a receiving part which receives the toner ejected from the ejection port, and configured to constitute a transport path for transporting the toner to the developing apparatus;
a pump for outputting the toner held in the storing portion from the ejection port toward the transport path unit; and
an optical sensor unit that is disposed in a passage area through which the toner output by the pump from the ejection port to the transport path unit passes, the optical sensor unit detecting whether or not toner is present.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
Hereinafter, an exemplary embodiment of the present invention will be described in detail with reference to the drawings. Note that the scope of the invention is not intended to be limited to the dimensions, materials, shapes, relative arrangements, and so on of the constituent elements described in this embodiment unless indicated otherwise.
Overall Configuration of Apparatus
The configuration of an image forming apparatus 1 in which the toner transport apparatus according to the present invention is applied, and an example of image forming operations, will be described with reference to the overall cross-sectional view in
The image forming apparatus 1 is an apparatus which forms an image on a recording material 4 using image forming units 6 (6Y, 6M, 6C, and 6K). The letters Y, M, C, and K appended to the reference signs indicate the four colors of yellow, magenta, cyan, and black, respectively. The following descriptions will omit these letters, and refer to the image forming units simply as “image forming units 6”, when there is no particular need to distinguish between the colors.
The image forming units 6 according to the present embodiment are process cartridges. The image forming units 6 (6Y, 6M, 6C, and 6K) include photosensitive drums 7 (7Y, 7M, 7C, and 7K), charging apparatuses 8 (8Y, 8M, 8C, and 8K), developing apparatuses 9 (9Y, 9M, 9C, and 9K), and cleaning blades 10 (10Y, 10M, 10C, and 10K).
Each photosensitive drum 7 is rotatably supported by a frame member of the corresponding image forming unit 6. The developing apparatuses 9 are provided with developing rollers 11 (11Y, 11M, 11C, and 11K), and each developing roller 11 is configured to be capable of making contact with and separating from the corresponding photosensitive drum 7. The developing roller 11 is rotationally driven to supply toner (developer) from the developing apparatus 9 to the photosensitive drum 7.
A control unit 60 includes a CPU, memory (this collectively refers to volatile memory and non-volatile memory), an input/output I/F, a bus, and the like, and performs various types of processing by communicating with an optical sensor unit 115, a display unit 90, and the like (described later), as well as with an external device such as an external information processing apparatus (a personal computer, a smartphone, or the like). The control unit 60 also receives image data by communicating with the exterior, reads out the received image data from the memory, and controls the various constituent elements of the image forming apparatus 1 to form an image based on the image data. The control unit 60 is a control unit constituted by a control circuit, an information processing apparatus, and the like. A power source unit 70 is a high-voltage power source that supplies power to various constituent elements of the image forming apparatus 1, such as the charging apparatuses 8 and a laser scanner unit 12. A drive unit 80 is a drive power source for driving various constituent elements of the image forming apparatus 1, and is a motor for rotationally driving the photosensitive drums 7, the developing rollers 11, an upstream-side screw 105, a downstream-side screw 124, a drive coupling 203, and various other types of rollers. The display unit 90 is a display apparatus for providing information to an operator, and any display apparatus, such as a liquid crystal panel, can be used. The display unit 90 may be configured as a touch panel so as to be capable of accepting operational inputs.
In the image forming operations, the control unit 60 causes a latent image based on the image data to be formed by causing each charging apparatus 8 to charge the surface of the corresponding photosensitive drum 7 and then irradiating the surface of the photosensitive drum with a laser using the laser scanner unit 12. Then, the latent image on the surface of the photosensitive drum is visualized as a toner image by the developing roller 11 supplying toner to the photosensitive drum 7. The developed toner image is transferred to an intermediate transfer belt 18 at a primary transfer part 20. Y, M, C, and K toner images are transferred consecutively to form a four-color toner image on the surface of the intermediate transfer belt 18. The four-color toner image is transported to a secondary transfer part 17 by the intermediate transfer belt 18 rotating.
Toner resupply cartridges 13 (13Y, 13M, 13C, and 13K), toner transport apparatuses 14 (14Y, 14M, 14C, and 14K), and toner transport drive apparatuses 15 (15Y, 15M, 15C, and 15K) are disposed below the image forming units 6 (6Y, 6M, 6C, and 6K), respectively. Each toner transport apparatus 14 functions as a transport path unit, and is driven by the corresponding toner transport drive apparatus 15 to transport and resupply toner to the image forming unit 6 from the toner resupply cartridge 13 as toner is consumed by the image forming unit 6.
A cassette 2 is provided in a lower part of the image forming apparatus 1, and the recording material 4, which is paper or the like, is held in the cassette 2. A cassette feed part 3 separates and feeds one sheet of the recording material 4 at a time by rotating, and that sheet is transported downstream by resist rollers 5.
An intermediate transfer unit 16 is provided above the developing apparatuses 9. The intermediate transfer unit 16 includes the intermediate transfer belt 18, primary transfer rollers 19, stretching rollers, and so on. The intermediate transfer unit 16 may be made removable from the image forming apparatus itself. The intermediate transfer unit 16 is disposed substantially horizontally so that the secondary transfer part 17 faces the transport path of the recording material 4.
The intermediate transfer belt 18, which opposes the photosensitive drums 7, is an endless belt capable of rotating, and is stretched upon a plurality of stretching rollers. On the inner surface of the intermediate transfer belt 18, the primary transfer rollers 19 (19Y, 19M, 19C, and 19K) are disposed opposite the photosensitive drums 7 (7Y, 7M, 7C, and 7K), respectively, with the intermediate transfer belt 18 located between the primary transfer rollers 19 and the photosensitive drums 7. The primary transfer parts 20 (20Y, 20M, 20C, and 20K) are formed between the primary transfer rollers 19 and the photosensitive drums 7. At each primary transfer part 20, a voltage is applied to the primary transfer roller 19 and the toner image is transferred onto the intermediate transfer belt 18 from the photosensitive drum 7.
The intermediate transfer belt 18 is interposed between a secondary transfer roller 21, which is a secondary transfer member, and a secondary transfer opposing roller 31, forming the secondary transfer part 17. The toner images transferred onto the intermediate transfer belt 18 undergo a secondary transfer to the recording material 4 at the secondary transfer part 17. Toner which could not be completely transferred onto the recording material 4 during the secondary transfer and which therefore remains on the intermediate transfer belt 18 is removed by a cleaning unit 22. The toner removed by the cleaning unit 22 is transported to and accumulated in a toner collection receptacle 24 via a collected toner transport unit 23.
Having undergone the secondary transfer of the toner image, the recording material 4 is transported further downstream (upward, in
Configuration for Toner Resupply
The toner resupply cartridge 13, and a configuration for transporting the toner, which are characteristic configurations of the present embodiment, will be described next with reference to
As illustrated in
The drive coupling 203 is disposed so as to transmit drive power to the cam gear 220 and to a toner resupply screw 209 located within the resupply frame member 201. When the toner resupply cartridge 13 is mounted in the image forming apparatus 1, the drive coupling 203 engages with a main body-side drive coupling (not shown). Drive power from the drive unit 80 is transmitted to the toner resupply cartridge side as a result.
As illustrated in
Here, one end of the pump 223 in the mounting direction is connected to the link mechanism 221 by a joining part 223b. The other end of the pump 223 in the mounting direction is fixed to the resupply frame member 201 by a connecting part 223c. Additionally, an inner space 223d of the pump 223 communicates with an inner space of the resupply frame member 201 (i.e., a toner storage chamber 201a which serves as a storage part and stores toner) via the connecting part 223c.
According to this configuration, the connecting part 223c of the pump 223 is fixed to the resupply frame member 201, and thus when the joining part 223b of the pump 223 moves back and forth in tandem with the link mechanism 221, a bellows part 223a of the pump 223 expands and contracts (see
A feeding port 101 is formed in an upper surface of the upstream-side transport portion 100. Toner supplied from the toner resupply cartridge 13 passes through the feeding port 101 and is supplied to a storage receptacle 108 within the upstream-side transport portion 100. The upstream-side transport portion 100 includes the upstream-side screw 105, which is disposed so as to be covered by the storage receptacle 108. Toner which has dropped from the feeding port 101 is distributed throughout the area where the upstream-side screw 105 is disposed. The toner is then transported in the direction of the downstream-side transport portion 120 by the upstream-side screw 105, which is rotationally driven by an upstream-side driving gear 103.
The downstream-side transport portion 120 includes a downstream-side wall surface 123. The downstream-side screw 124 is disposed so as to be covered by the downstream-side wall surface 123. A part of the downstream-side transport portion 120 furthest on the upstream side (a lower part in
Detailed Description of Upstream-Side Transport Unit 100
The toner transport apparatus 14 will be described in detail next with reference to
As illustrated in
As illustrated in
The optical sensor unit 115 includes a light-emitting substrate 115a, serving as a light-emitting unit and including a light-emitting element and driving circuitry thereof, and a light-receiving substrate 115b, serving as a light-receiving unit and including a photo acceptance unit and driving circuitry thereof. The light-emitting substrate 115a of the optical sensor unit 115 is provided on the outer side of one of the pair of light-transmissive members 107. The light-receiving substrate 115b is provided on the outer side of the other light-transmissive member 107. In other words, the light-emitting substrate 115a, one of the light-transmissive members, the toner passage area, the other of the light-transmissive members, and the light-receiving substrate 115b are disposed in that order in the direction connecting the pair of light-transmissive members 107. According to this structure, an optical path P from the light-emitting substrate 115a to the light-receiving substrate 115b intersects with the toner passage area.
As a result, toner can be detected by the optical sensor unit 115, which makes it possible to determine whether or not there is toner. In other words, if there is no toner in the optical path P, through which light emitted from the light-emitting substrate 115a under the control of the control unit 60 reaches the light-receiving substrate 115b via the pair of light-transmissive members 107, and the light-receiving substrate 115b has therefore detected the light, the control unit 60 can determine that no toner is present. On the other hand, if the light is blocked by the toner and the light-receiving substrate 115b cannot detect the light under predetermined conditions, the control unit 60 can determine that toner is present. Note that the control unit 60 may perform the determination in accordance with the optical intensity of the light reaching the light-receiving substrate 115b.
A light-emitting diode (LED) which emits light such as infrared light can be used as the light-emitting element included in the light-emitting substrate 115a, for example. However, the wavelength range of the light is not limited thereto, and the light may be visible light instead. Another light source member, such as a semiconductor laser (LD), may be used instead of an LED. A known light-receiving substrate, e.g., a photosensor, can be used as the photo acceptance unit included in the light-receiving substrate 115b. Any other optical sensor can be used as well, as long as the sensor can determine whether or not an object is present in an optical path using light.
A material which is transmissive with respect to the wavelength range of the light emitted from the light-emitting substrate 115a, e.g., an acrylic resin, can be used favorably as the light-transmissive members 107. The light-transmissive members 107 may have any shape and be provided in any position as long as the optical path can be formed in the passage area through which the toner passes when falling, i.e., may be non-circular. Additionally, for the purpose of defining the optical path, optical members such as rod-shaped lenses made of an acrylic resin may be used as the light-transmissive members 107, or optical members may be disposed in the vicinity of the light-transmissive members 107.
An optical intensity at which the light-receiving substrate 115b receives light when the light-emitting substrate 115a emits light at a predetermined optical intensity is stored in the memory of the control unit 60 in advance. Whether or not toner is present in the passage area is then determined by comparing the optical intensity at which the light-receiving substrate 115b receives light with the stored optical intensity when the light is emitted. In other words, when light having at least a predetermined optical intensity has been received by the light-receiving substrate 115b, the control unit 60 determines that there is no toner or that there is almost no toner, and executes predetermined processing. Alternatively, time information on the time at which the light-receiving substrate 115b receives light when the light-emitting substrate 115a emits light at a predetermined optical intensity is stored in the memory of the control unit 60 in advance. In this case, whether or not toner is present in the passage area is determined in accordance with the length of a time, in a predetermined period, for which the light-receiving substrate 115b receives light, in excess of a threshold time. In other words, when light has been received by the light-receiving substrate 115b for at least a predetermined time, the control unit 60 determines that there is no toner or that there is almost no toner, and executes predetermined processing.
Here, the predetermined processing executed by the control unit 60 when it is determined that there is no toner or there is almost no toner includes, for example, displaying a message prompting the toner resupply cartridge to be replaced in the display unit 90.
As illustrated in
Method for Detecting Remaining Amount During Operations Performed when Resupplying Toner
A method for detecting the remaining toner amount during operations for resupplying toner from the toner resupply cartridge 13 will be described next with reference to
As described above, when the amount of toner remaining in the developing apparatus decreases or decreases from a predetermined amount, the control unit 60 performs control so that the developing apparatus 9 is resupplied with toner from the toner resupply cartridge 13. The control unit 60 obtains the amount of toner remaining in the developing apparatus 9 through a given method, such as optical detection or weight-based detection, and sends a resupply signal to the toner transport apparatus side when the remaining amount has reached zero or has dropped below a predetermined threshold. As illustrated in
As illustrated in
The supply of the toner in the upstream-side transport portion 100 will be described next with reference to
As illustrated in
When the resupply of the toner begins, the state transitions to that illustrated in
Preferably, when projected onto the passage area as seen from a direction intersecting with the direction in which the toner is ejected, the pair of light-transmissive portions are disposed so as to overlap with a region enclosed within (i) the first trajectory, (ii) the second trajectory, (iii) a line connecting the upper and lower ends of the ejection port, and (iv) a wall surface of the receiving part. This ensures that the optical path of the optical sensor overlaps with the toner passage area.
To take this from a different perspective, preferably, when projected onto the passage area as seen from a direction intersecting with the direction in which the toner is ejected, the light-receiving unit is disposed so as to overlap with the region enclosed within (i) the first trajectory, (ii) the second trajectory, (iii) a line connecting the upper and lower ends of the ejection port, and (iv) a wall surface of the receiving part. This also ensures that the optical path of the optical sensor overlaps with the toner passage area.
Through this configuration, the optical sensor can detect the presence/absence of toner discharged from the ejection port 106a, via the light-transmissive members 107. If no toner is discharged from the ejection port 106a despite resupply operations being performed, the control unit 60 can determine that the toner within the toner resupply cartridge 13 has been exhausted. This makes it possible to quickly determine that there is no toner left in the developer container. Note that if the light-transmissive members 107 have a function for focusing light, and an optical member which reflects the focused light onto a given position is furthermore provided, it is not necessary for the position of the light-receiving unit of the light-emitting substrate 115a to overlap with the toner drop trajectory when viewed from a direction intersecting with the direction in which the toner is ejected. On the other hand, if the light-transmissive members 107 do not have such functions, it is necessary for at least part of the light-receiving unit of the light-emitting substrate 115a to overlap with the toner drop trajectory when viewed from a direction intersecting with the direction in which the toner is ejected.
Conditions for determining whether or not toner is present using an optical sensor will be considered with reference to
The present embodiment assumes that the toner passes through the horizontal channel of the L-shaped channel 106, and is then ejected horizontally from the ejection port 106a. Assume that T1 represents the toner ejected from the lower end of the ejection port 106a, T2 represents the toner ejected from the upper end of the ejection port 106a, T1_0(x1, z1) represents coordinates of the toner T1 at the time of ejection, and T2_0(x1, z2) represents coordinates of the toner T2 at the time of ejection. Assume also that the direction in which the toner is ejected is the forward direction along an x-axis, and the direction in which the toner falls (downward in the vertical direction) is the forward direction along a z-axis.
Assuming the initial velocity of the toner is V0 m/s, the toner moves at a constant velocity motion in the horizontal direction at a velocity Vx of V0, and falls freely in the vertical direction at a velocity Vz of gt. At this time, an amount of displacement from the initial coordinates t seconds after the ejection is (V0t,(½)gt2), and the toner drop trajectory is given as z=(g/2V02)·x2. Therefore, the coordinates of the toner T1 at t seconds after ejection are T1_t(x1+V0t, z1+½·gt2), and the coordinates of the toner T2 are T2_t (x1+V0t, z2+½·gt2).
For the toner ejected from the ejection port 106a, the range of the drop trajectory is defined assuming an initial velocity of constant-velocity linear motion at V0 m/s and free-fall motion. This is based on the assumption that most of the toner ejected from the ejection port 106a is ejected in a cluster of particles adjacent to each other, so that the effects of air resistance can be ignored.
The movement trajectory of the toner T1, which has coordinates of T1_0 (x1, z1) at the time of ejection, can also be defined by the following formulas. The coordinates of the toner T1 are expressed as follows:
X=x1+V0t (1),
Z=(z1+½·gt2) (2)
Using formulas (1) and (2) to eliminate t provides the following formula (3).
Z=z1+½·g((X−x1)/V0)2 (3)
Substituting the value of X in this formula (3) as appropriate makes it possible to obtain the value of the Z-coordinate at any X-coordinate for the toner ejected from the lower end of the ejection port 106a. In other words, this formula (3) expresses the movement trajectory of the toner ejected from the lower end of the ejection port 106a in
Likewise, the movement trajectory of the toner T2, which has coordinates of T2_0 (x1, z2) at the time of ejection, can also be defined by the following formulas. The coordinates of the toner T2 are expressed as follows:
X=x1+V0t (4),
Z=(z2+½·gt2) (5)
Using formulas (4) and (5) to eliminate t provides the following formula (6).
Z=z2+½·g((X−x1)/V0)2 (6)
Substituting the value of X in this formula (6) as appropriate makes it possible to obtain the value of the Z-coordinate at any X-coordinate for the toner ejected from the upper end of the ejection port 106a. In other words, this formula (6) expresses the movement trajectory of the toner ejected from the upper end of the ejection port 106a in
In this manner, the above formulas (3) and (6) make it possible to define the passage area (passage trajectory) of the toner ejected from the ejection port 106a. In the configuration according to the present embodiment, the light-transmissive members 107 are provided so that the optical path of the optical sensor overlaps with this toner passage area.
As such, the optical path P can be caused to intersect with the toner passage area by ensuring that the light-transmissive members 107 and the photo acceptance unit of the light-emitting substrate 115a at least partially fall within this range. Preferably, the light-transmissive members 107 are disposed so as to cover the upper and lower ends of the toner passage area, as in the example illustrated here. By doing so, any toner discharge is reliably detected by the optical sensor, which improves the accuracy of the detection.
Here, the initial velocity V0 is a predetermined value determined by the characteristics of the toner, such as the material and shape, the performance of the pump 223, such as the cross-sectional area of the pump 223 and the stroke during back-and-forth movement, and the position and size of the ejection port 106a. In other words, the first trajectory and the second trajectory described above are also determined by the characteristics of the toner, such as the material and shape, the performance of the pump 223, such as the cross-sectional area of the pump 223 and the stroke during back-and-forth movement, and the position and size of the ejection port 106a. As such, the area through which the toner passes after ejection can be calculated in advance using the above formulas. Therefore, disposing the light-transmissive members 107 so as to overlap with the toner passage area when the light-transmissive members 107 are projected makes it possible to reliably detect whether or not there is any toner remaining.
The shape of the channel through which the toner output from the pump is ejected into the storage receptacle 108 is not limited to being L-shaped. Furthermore, the method for ejecting the toner is not limited to horizontal ejection. For example, the toner can be allowed to fall freely, or can be ejected at an angle. Even in such a case, the light-transmissive members 107 and the optical sensor may be disposed in accordance with the trajectory which the toner is expected to follow while falling.
As described thus far, according to the present invention, the light transmitting members are provided in the vicinity of a path through which the toner passes, and thus the discharged toner can be detected directly. This makes it possible to quickly determine that the toner in the toner resupply cartridge has run out or is close to running out, which in turn makes it possible to improve usability.
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. 2019-207173, filed on Nov. 15, 2019, which is hereby incorporated by reference herein in its entirety.
Number | Date | Country | Kind |
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JP2019-207173 | Nov 2019 | JP | national |
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Number | Date | Country | |
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20210149324 A1 | May 2021 | US |