Patent Grant
7020422
1. Field of the Invention
The present invention relates to an image forming apparatus such as a printer, a copying machine, or a facsimile machine, and more particularly, to a transfer device (apparatus) and a transfer member used in the image forming apparatus.
2. Related Background Art
In recent years, the development of image forming apparatuses such as printers, copying machines, and facsimile machines capable of operating at higher speed, having an increased number of functions and capable of forming images in an increased number of colors has progressed. Such image forming apparatuses heretofore proposed use various image forming systems. Among them, inline-type image forming apparatuses in which image forming means using a plurality of different colors are arranged in a row to successively transfer toner images directly onto a belt or onto a transfer material born by a transferring belt in a multiple transfer manner such that toner images are superposed one on another are considered to go mainstream as a color image forming apparatus in future because they have high operating speed and are capable of forming a multicolor image.
Inline-type image forming apparatuses are divided into a type (intermediate transfer type) in which toner images are temporarily transferred onto an intermediate transfer member in a multiple transfer manner and are thereafter transferred to a transfer material, and another type (transferring belt type) in which a transfer material is attracted to a transferring belt and multiple transfer is performed directly on this transfer material. From the viewpoint of reducing the size and manufacturing cost of the apparatus, it can be said that apparatuses of the latter type having a smaller number of system constituent elements are more advantageous.
Transferring belt type image forming apparatuses require a process in which, in the case of four-full-color image forming, transfer to an object such as a transfer material (e.g., paper or a transparent resin film) or a transferring belt having an instability factor with respect to the resistance value is performed four times and therefore have the disadvantage of being not sufficiently stable with respect to the kind of transfer material and conditions in environments where they are installed. Also, they require a considerably high transferring voltage for causing a sufficiently large transfer current at the time of automatic double-side image forming including repeating an image forming operation on a transfer material after the resistance of the transfer material has been increased by evaporation of water added at the time of fixation previously performed, or in an overhead transparency (OHT) mode in which image forming is performed on a transparent resin film which is insulating in the thickness direction.
Also, transfer-belt-type image forming apparatuses have four image forming stations (hereinafter referred to briefly as “station”) arranged between a position on the upstream side in the transfer material conveyance direction and a position on the downstream side in this direction. When the stations perform transfer successively from the upstream side, the transfer material or the transferring belt is charged up by receiving transfer charge, so that the transferring voltage required by the stations is increased with the distance from the upstream end position.
In a transferring part, discharge is caused between a photosensitive drum, a transfer material, a transferring belt, and a transfer member, e.g., (a transferring roller) to effect toner transfer and to move charge to the transfer material. If the transferring voltage is excessively high, excessive discharge or abnormal discharge occurs between the members, to which the high voltage is applied, resulting in failure to suitably transfer toner. In particular, if a leak site or the like exists between the transfer member and the transferring belt, discharge is concentrated at the leak site to cause deterioration in transferring performance.
Further, in a reversal developing system, variation in potential contrast between a dark portion potential and a light portion potential on an organic photo-conductive (OPC) material as seen from a transfer member leads to a change in amount of charge given to the OPC. A dark portion potential portion having a high transfer contrast is given transfer charge of a polarity opposite to that of the OPC charge potential, so that charging failure due to limitation of the increase in OPC potential at the time of subsequent image forming or OPC ghost is liable to occur frequently.
To ensure sufficiently high conductivity of a transferring roller, an electron-conductive filler such as carbon black or a metal oxide may be dispersed in a material for the transferring roller. In such a case, however, local resistance nonuniformity can occur easily due to nonuniformity of dispersion of the filler. In particular, a portion where the filler condenses becomes a leak site, at which a current is concentrated and can flow easily if the transferring voltage is high. The conduction mechanism in an electron-conductive material is such that electrons move between filler particles while hopping by the tunnel effect, and the current can be abruptly caused to flow readily and the resistance value becomes small when the applied voltage is increased.
To solve this problem, a method has been proposed in which an ion-conductive material whose resistance with respect to the applied voltage is comparatively stable and which has reduced local resistance nonuniformity is used to form a transfer member.
Generally, the transferring efficiency is improved if the transferring voltage (transferring bias) is increased. However, the electronic conductor type roller has a larger resistance value when the transferring voltage is low (e.g., lower than 500 V indicated in
The ionic conductor type roller has a linear current-voltage characteristic as shown in
With the ionic conductor type of transferring roller having the advantage that variation in resistance with respect to the applied voltage is small and that local resistance nonuniformity is also low, there arises a problem in that the resistance increases about ten times higher (at a rate of about one digit of magnitude in terms of common logarithm) to cause a reduction in transferring efficiency by a paper feeding durability test which is performed by feeding many paper (hereinafter referred to as “durability test”).
An object of the present invention is to provide an image forming apparatus, a transfer device and a transferring roller in which it is possible that a change in resistance due to a change in applied voltage is limited and transferring efficiency after a durability test is sufficiently high.
Another object of the present invention is to provide an image forming apparatus including an image bearing member and a transfer member, wherein an image on the image bearing member is transferred to a member to be transferred by applying a voltage to the transfer member, and the transfer member has an ionic conductor part which contains an antioxidant.
Further another object of the present invention is to provide a transfer device including a transfer member and a voltage applying means, wherein the voltage applying means applies a voltage to the transfer member and an image is transferred to a member to be transferred, and the transfer member has an ionic conductor part which contains an antioxidant.
Still further object of the present invention is to provide a transferring roller including a metal core and an ionic conductor part provided on the metal core, wherein the ionic conductor part contains an antioxidant.
These and other objects and features of the present invention will become apparent from the following detailed description of preferred embodiments of the invention.
Embodiments of the present invention will be described with reference to the accompanying drawings. The same reference numerals in the drawings indicate the same components or functions, and the description for the same components or functions will not be repeated.
First Embodiment
The schematic construction of the laser printer (hereinafter referred to as “image forming apparatus”) will be described with reference to
The image forming apparatus shown in
A sheet-feeding cassette 14 in which a transfer material (recording material) P provided as the other member (a member to be transferred) for image forming (printing) is accommodated is provided in a lower section of the image forming apparatus. As transfer material P, plain paper, thin paper, carton, an envelop, an OHT sheet (transparent resin film for use in an overhead projector), etc., may be used.
A registration roller 12 for feeding transfer material P at predetermined timing and an attraction roller 5 for attracting transfer material P to the surface of the transferring belt 1 are provided above a left end of the sheet-feeding cassette 14 as viewed in
The image forming stations SM, SC, SY, and SK are substantially identical to each other in construction and each have a photosensitive drum 6 provided as an image bearing member, a charging roller (primary charger) 7 for uniformly charging the surface of the photosensitive drum 6, an exposure device 8 for exposing the surface of the photosensitive drum 6 after charging to form an electrostatic latent image, a developing device 9 for attaching toner to the electrostatic latent image to develop a toner image, a transferring roller (transfer member) 4 for transferring the toner image on the photosensitive drum 6 to the transfer material P, and a cleaning device 10 for cleaning the surface of the photosensitive drum 6 after toner image transfer.
A fixing device 11 for fixing the toner image transferred to transfer material P and a sheet-discharge tray 13 onto which transfer material P after toner image fixing is discharged are provided above the image forming station SK on the most downstream side of the arrangement of the stations.
The operation of the above-described image forming apparatus will be described as well as details of each of the above-described members, devices, etc.
The photosensitive drum 6 is an electrophotographic photosensitive member formed into the shape of a drum, and has a photosensitive layer formed on the surface of a cylindrical electroconductive base member. For example, OPC or amorphous silicon can be used to form the photosensitive layer. The photosensitive drum 6 is driven to rotate in the direction of the arrow at a predetermined process speed (peripheral speed) by a drive means (not shown).
The photosensitive drum 6 driven and rotated in the direction of the arrow has its surface uniformly charged at a predetermined potential with a predetermined polarity by means of the charging roller 7.
On the surface of each photosensitive drum 6 after changing, an electrostatic latent image is formed by each exposure device 8. The exposure device 8 includes of a laser diode, a polygon scanner, a lens group, and a reflecting mirror (not shown). The exposure device 8 selectively exposes the photosensitive drum 6 surface to the laser beam on the basis of image information to form an electrostatic latent image corresponding to the image information.
The electrostatic latent image formed on the surface of each photosensitive drum 6 in this manner is developed by the developing device 9. In the developing devices 9, magenta, cyan, yellow and black developers (toners) are respectively contained. Each of these color toners is attached to the electrostatic latent image on the corresponding photosensitive drum 6 by means of a developing sleeve placed so as to face the photosensitive drum 6. The electrostatic latent image on each photosensitive drum 6 is thereby developed as a toner image in each of the colors, i.e., magenta, cyan, yellow and black. Each of the above-mentioned color toners is nonmagnetic toner including no magnetic material. Each toner is attached to the electrostatic latent image by a one-component contact developing method. In this embodiment, image forming is performed, typically, by using a reversal developing method in which a negatively charged toner is used, a dark portion potential of −700 V and a developing potential of −400 V are set, and transfer is performed by using a positive transferring bias.
The transferring belt 1 is stretched between the drive roller 2 and the driven roller 3. With the rotation of the drive roller 2 in the direction of the arrow, the transferring belt 1 is driven to rotate in the direction of arrow R1 at the same peripheral speed as the photosensitive drum 6. Transfer material P fed from the sheet-feeding cassette 14 by a feed roller (not shown) passes the registration roller 12 and then passes the nip between the transferring belt 1 and the attraction roller 5 to be attached to the surface (outer peripheral surface) of the transferring belt 1 by being electrostatically attracted to the same.
The attraction roller 5 has a metal core having a diameter of 6 mm and a solid rubber portion molded on the metal core. With this construction, a high bias voltage can be applied to the metal core. In this case, the attraction roller 5 is a solid rubber roller having a diameter of 12 mm and having EPDM rubber in which carbon black is dispersed for resistivity adjustment. A strip of metallic foil having a width of 1 cm is wrapped around the outer peripheral surface of the roller to adjust the resistivity so that the resistance is 1×105 Ω when a voltage of 500 V is applied between the surface and the metal core. An attraction bias is generated from a high-voltage substrate according to a signal determined by a DC controller (not shown) according to an environment in which the image forming apparatus is used and image forming conditions (printing conditions). The attraction voltage and current can be monitored through an A/D converter (not shown) on the high-voltage substrate.
Each transferring roller 4 is placed inside the transferring belt 1 at such a position as to face the photosensitive drum 6 and to pressurize the back surface of the transferring belt 1 so that the surface of the transferring belt 1 contacts the photosensitive drum 6. Each time transfer material P attached to the transferring belt 1 passes one of the image forming stations SM, SC, SY, and SK, a transferring bias is applied to the transferring roller 4 from a power supply 20 which is a voltage application means. The toner images on the photosensitive drums 6 are thereby transferred successively to the surface. Thus, the toner images in the four colors are superposed one another on transfer material P.
After the toner images have been transferred to transfer material P, transfer material P is separated from the surface of the transferring belt 1 by the curvature effect in the vicinity of the drive roller 2 on the most downstream side of the transferring belt 1, and is thereafter fed into the fixing device 11. On the other hand, from the photosensitive drum 6 after toner image fixation, toner (residual toner) left on the surface without being transferred to transfer material P at the time of transferring is removed by the cleaning device 10 to be used for the next image forming.
Transfer material P fed into the fixing device 11 is heated and pressurized by a fixing roller 11a and a pressure roller 11b to fix the toner image on the surface. Transfer material P in which, on one surface (first surface), image forming has been completed is discharged onto the sheet-discharge tray 13. Thus, four-full-color image forming on one surface of transfer material P is completed.
On the other hand, image forming on both the surfaces (the first surface, and the second surface opposite side of the first surface) of transfer material P may be performed as described below. Transfer material P having the toner image fixed on its first surface is supplied to an automatic double-side feeding unit (not shown) to be turned upside down, and is again attracted and attached to the surface of the transferring belt 1. To the second surface of transfer material P, toner images in the respective colors are transferred by the image forming stations SM, SC, SY, and SK and are fixed by the fixing device 11, as are those transferred to the first surface. Transfer material P is thereafter discharged onto the sheet-discharge tray 13. Thus, four-full-color image forming on the two surfaces of transfer material P is completed.
The above-described transferring belt 1 has its resistivity adjusted in such a manner that an ion conductive agent is added to polyvinylidene fluoride (PVdF) resin so that the volume resistivity is 1×109 Ω·cm. The transferring belt 1 is formed in a single layer structure having a thickness of 100 μm. The volume resistivity according to the present invention is set by normalizing with respect to the belt thickness a measured value obtained by using a measuring probe in accordance with JIS method K6911 and applying voltage of 100 V with a high-resistance meter, R8340 manufactured by ADVANTEST Corporation.
From the viewpoint of electrostatically attracting transfer material P, it is desirable that the volume resistivity of the transferring belt 1 be high. However, if the volume resistivity is excessively high, the transferring belt 1 itself is charged up and a need for a high transferring voltage (transferring bias) arises as well as a need for an additional mechanism for eliminating charge on the transferring belt 1. In setting the resistivities of the transferring parts to a high value according to various requirements, therefore, it is desirable to set the volume resistivity of the transfer member, i.e., the transferring roller 4, within a suitable range instead of unnecessarily increasing the resistivity of the transferring belt 1 as the transferring and conveying member. More specifically, if the transferring belt 1 has a volume resistivity equal to or higher than 1×1012 Ω·cm, potential attenuation in the transferring belt 1 during movement between each pair of image forming stations, i.e., self-attenuation, cannot be expected. In such a case, a need arises to use means for eliminating charge on the transferring belt 1, e.g., a corona charger. Therefore this setting is considered undesirable from the viewpoint of simplifying the apparatus and reducing the manufacturing cost. The transferring roller 4 can be increased in thickness of the resistance layer unlike the transferring belt 1. Even if a material having a lower volume resistivity is used for the transferring roller 4, the resistivity thereof as the transfer member can be set to a high value and a high-resistance system can be constructed while avoiding charge-up. In this embodiment, by considering achievement of self-attenuation in the transferring belt 1 and realization of the transferring belt 1 with a sufficiently high attraction for transfer material P, the resistance of the transferring belt 1 is set to the above-mentioned value (1×109 Ω·cm).
The construction of the transferring roller 4 used in this embodiment will be described in detail with reference to
The transferring roller 4 has an elastic layer 4b which is formed on the metal core 4a as an ionic conductor part. A single-layer roller having a metal core diameter of 6 mm and an outer diameter of 12 mm was used as the transferring roller 4. That is, the ionic conductor part is a surface layer. The elastic layer of the roller is prepared by mixing epichlorohydrin rubber with nitrile-butadiene rubber (NBR) and blending a diphenylamine-based antioxidant 4c therein. The resultant is formed by extrusion molding and polished. The voltage dependence of the roller resistivity is limited because of the ion-conductive property. The roller resistivity in the case where a strip of metallic foil having a width of 1 cm is wrapped around the outer peripheral surface of the roller is 5.5×106 Ω when a voltage of 250 V is applied between the surface and the metal core, and 4×106 Ω when a voltage of 1000 V is applied.
As described above, in the transfer devices in an in-line system image forming apparatus, the transfer material P and the transferring belt 1 are charged up at an image forming station at a downstream position by transferring charge supplied from an image forming station at an upstream position, so that the transferring voltage applied from the image forming station closer to the downstream end must be set to higher value in order to cause the same transferring current to flow. Therefore, in the transfer devices in such conventional in-line system image forming apparatuses, a condition may occur easily such that the transferring voltage is abnormally high and the transferring efficiency is liable to become lower due to abnormal discharge. Such a phenomenon is particularly considerable at the time of double-sided image forming or image forming on an OHT sheet requiring a higher transferring voltage.
For example, while the transferring voltage at the time of double-sided image forming in an intermediate transfer type of image forming apparatus ordinarily used is about 2 kV, the necessary condition for double-sided image forming in a transferring belt-type of image forming apparatus is a transferring voltage of 3 kV at the final image forming station SM for the fourth color, even though the sufficient transferring voltage at the image forming station SM for the first color is 2 kV. This means that the transfer material P and the transferring belt 1 are charged up by 1 kV.
Also, in the transferring roller formed without blending an antioxidant therein, an increase in resistivity of about ten times as a result of the durability test was observed in the range from 250 to 3000 V ordinarily set as a transferring bias range. In contrast, in the case of the transferring roller 4 formed by blending an antioxidant therein, the increase in resistance was limited to about 102/5Ω. It is preferable to limit the change in resistance to 101/2Ω or less. Also, it is preferred that the difference between the resistivity of the transferring roller when a voltage of 1000 V is applied and the resistivity of the transferring roller when a voltage of 250 V is applied does not exceed 101/5Ω.
To limit the inflow of transferring current to the paper passing portion and the non-paper-passing portion, it is necessary to reduce the impedance of the non-paper-passing portion as seen from the transfer member. Accordingly, it is necessary to set the resistivity of the transfer member to a certain level or higher.
In a case where an electron-conductive transfer member is used, a reduction in resistivity occurs in a high-voltage range and there is therefore a need to set the resistance of the member to a value approximately equal to or larger than 108 Ω. In contrast, in a case where an ion-conductive transfer member is used, the reduction in resistivity in the high-voltage range is small and the change in resistance during a durability test is also small. In this case, therefore, it is desirable to set the resistance of the transfer member to a value equal to or higher than 106 Ω.
Also, to cause a current necessary for transfer (e.g., about 10 μA) to flow by using a practical high-voltage power supply (having a maximum voltage of 10 kV, for example), it is desirable to limit the resistance of the transfer member to a value of 109 Ω or less.
Accordingly, it is preferred that the resistance of the transfer member when a voltage of 1000 V is applied be 1×106 to 1×109 Ω.
As described above, in the in-line system image forming apparatus using the transferring belt 1 in this embodiment, an ion-conductive transferring roller formed by blending an antioxidant therein is used for the purpose of preventing occurrence of an image defect at the time of double-sided image forming requiring a particularly high transferring voltage, and use of this transferring roller provides a large effect.
Second Embodiment
In this embodiment, in a case of an in-line system image forming apparatus using a transferring belt, an ion-conductive transfer member having a surface not smooth, e.g., a surface in sponge form is used to prevent occurrence of an image defect when a high transferring voltage is applied. Also, an antioxidant is blended in the material forming the transfer member to enable the desired performance to be maintained during a durability test. The construction of the image forming apparatus of this embodiment is the same as that of Embodiment 1 (shown in
As described above in the description of Embodiment 1, in a system using the transferring belt 1 in an in-line system image forming apparatus, there is a need to set the transferring voltage from an image forming station at a downstream position to a higher value because of charge-up in the transfer material P and the transferring belt 1, and there is a problem in that image defects can occur easily.
The maximum voltage at the time of double-sided image forming is about 3 kV even in the case of a transferring belt type of image forming apparatus. Under such a condition, it is possible to prevent occurrence of image defects during a durability test by using an ion-conductive transfer member formed by blending an antioxidant.
In some case of image forming on an OHT sheet which is substantially insulating in the thickness direction, the necessary transferring voltage for transfer to the OHT sheet reaches 6 kV.
As a means for preventing an image defect due to separation discharge, a resistivity treatment is ordinarily performed on the surface of OHT sheets. However, the base film of ordinary OHT sheets is an insulating material such as polyethylene telephthalate (PET) and the thickness thereof is 100 μm or more. Therefore, the voltage necessary for transfer is high and charge-up is considerable. Therefore, the downstream-side image forming stations must be operated under severe conditions with respect to the transferring voltage and occurrence of image defects.
In this embodiment, an ion-conductive sponge roller 41 such as shown in
If the surface of the transferring roller 4 is smooth, the threshold value at which discharge starts between the transferring roller 4 and the back surface (reverse surface) of the transferring belt 1 is high. This is because the discharge start voltage (discharge threshold value) depends only upon air pressure and the intensity of the electric field therebetween, as explained in discharge theories including Pachen's law. Since the electric field between parallel electrodes is a parallel electric field (uniform electric field), the threshold value of discharge between the two members is maximized.
In a separation step including rotating and moving the transferring roller 4 and the transferring belt 1, the voltage across the gap becomes extremely high, so that discharge is necessarily excited at an ordinary transferring voltage regardless of the discharge threshold value.
When discharge occurs under a high-discharge-threshold value condition as between smooth parallel surfaces, the amount of charge moved by one discharge is extremely large. In such an event, charge balance on at the back surface of the transfer material P can be easily lost and a large discharge shock is caused. Therefore, when an OHP sheet is used, the possibility of an image defect such as an abnormal discharge pattern typified by a zigzag discharge pattern or a dotted pattern due to nonuniformity of back charge on the sheet is high.
On the other hand, the transferring roller 41 having a sponge-like surface has extremely small irregularities in its surface, which cause a non-uniform electric field to reduce the discharge threshold value and to reduce the extent of movement of charge per discharge.
That is, charge transfer is effected even by many minute discharges, so that a large discharge which may lead to occurrence of an image defect can be prevented without changing the transferring current.
In this embodiment, a sponge-like elastic layer 41b provided as an ionic conductor part on a metal core 41a is used. More specifically, an ion-conductive sponge roller was used which was made in such a manner that a diphenylamine antioxidant 41c is blended with a mixture of NBR and epichlorohydrin rubber, a cylindrical tube is formed by extrusion molding from this material, and this tube is vulcanized and foamed in a pressured atmosphere. In this manner, a sponge roller having a metal core diameter of 6 mm, an outside diameter of 12 mm, a product hardness Asker C of 30° with respect to a load of 500 g, an actual resistance of 1×107 Ω measured by the above-mentioned resistance measuring method when 1000 V was applied and a sponge surface cell diameter of about 100 μm was made.
The surface roughness of this sponge roller measured with a non-contact surface roughness meter was 40 μm. Image forming on an OHT sheet was performed by using this sponge roller and operating the image forming apparatus in accordance with Embodiment 1. The operation in the OHT mode is performed by changing the transferring voltage by a command from a host computer. As a comparative example, image forming using an electron-conductive solid roller was performed by setting transferring voltages of 2 kV, 3.5 kV, 5.0 kV, and 6.5 kV in at image forming stations successively from the upstream side. In this case, considerable image scatter and paper traces in the non-paper-passing portion were caused.
Image forming using the ion-conductive sponge roller of this embodiment was performed under the same conditions to continuously output a good image during a durability test.
As described above, in the case of transfer at a high voltage such as image forming with respect to the OHC sheet, the transfer member in a sponge form or the like which is ion-conductive and having a non-smooth surface structure is used to prevent an image defect on an OHT sheet, e.g., an abnormal discharge pattern such as a zigzag discharge pattern or a dotted pattern due to abnormal discharge, thereby limiting excessive discharge while causing many small discharges to move transferring charge. Thus, the present invention has the effect of preventing occurrence of image defects. Also, blending of an antioxidant is effective in maintaining the improved performance during a durability test.
The embodiments of the present invention have been described by way of example with respect to an in-line four-full-color image forming apparatus (laser printer) which uses a transferring belt, and which is particularly effective when the transfer device in accordance with the present invention is used. However, the transfer device of the present invention is not limited to this image forming apparatus. For example, it can be applied to an image forming apparatus in which an intermediate transferring body 50 (e.g., an intermediate transferring belt, or an intermediate transferring drum) such as shown in
According to the present invention, as described above, variation in resistivity of the transfer member accompanying a change in applied voltage is limited and high transferring efficiency can be maintained during a durability test, so that improved images can be obtained during a long period of time.
While the present invention has been described with respect to preferred embodiments thereof, the present invention is not limited to the described embodiments and the described embodiments can be modified variously within the technical scope of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2001-331369 | Oct 2001 | JP | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 5809387 | Takeuchi et al. | Sep 1998 | A |
| 6041209 | Murata | Mar 2000 | A |
| 6078775 | Arai et al. | Jun 2000 | A |
| 6308019 | Miyashiro et al. | Oct 2001 | B1 |
| 6477339 | Yano et al. | Nov 2002 | B1 |
| 20010021736 | Murata | Sep 2001 | A1 |
| 20020006294 | Yano | Jan 2002 | A1 |
| 20030104295 | Niimi | Jun 2003 | A1 |
| Number | Date | Country |
|---|---|---|
| 09269679 | Oct 1997 | JP |
| 11030897 | Feb 1999 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20030081226 A1 | May 2003 | US |
