Complementing Toner for Embossed Sheet Fixation

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Solution Overview

Problem

In electrophotographic image forming apparatuses, the fixation performance of toner on embossed sheets is compromised due to air layers generated between the toner and the fixing member, leading to toner removal and transfer issues, as existing techniques either degrade the texture of the sheet or require excessive transparent/white toner to reduce surface roughness.

Innovation Solution

An image forming apparatus that detects irregularities on embossed sheets and supplies complementing toner with higher thermal conductivity to fill gaps between toner images, specifically applying white toner to recesses and protrusions to enhance heat transfer and adhesion, while maintaining the sheet's texture and reducing toner consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If transparent/white toner is applied to reduce surface roughness of embossed sheets, then fixation performance is improved, but the texture of the sheet is degraded and excessive toner is required

Engineering Contradiction:

Improvefixation performanceVSAvoidtexture of sheet

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The patent applies complementing toner selectively only to the recess portions of the embossed sheet where toner is buried, rather than uniformly across the entire surface. This local application fills the gaps between toner images in recess areas without covering the protrusion surfaces, thereby maintaining the sheet's texture while improving fixation performance in the critical regions where air layers cause problems.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent performs preliminary detection of the sheet surface to identify recess portions before applying complementing toner. By detecting the surface topology in advance and targeting only the recess areas for toner supply, the system prevents excessive toner consumption and avoids degrading the overall sheet texture while still addressing the fixation issues in recess regions.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If complementing toner is supplied to fill gaps between toner images, then fixation performance is improved, but toner consumption increases

Engineering Contradiction:

Improvefixation performanceVSAvoidtoner consumption

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent supplies complementing toner only to the recess portions where gaps between toner images exist, rather than uniformly across the entire sheet surface. This localized toner application fills the critical gaps that cause fixation problems while minimizing overall toner consumption by avoiding unnecessary toner deposition on protrusion areas and non-gap regions.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system performs preliminary detection of the sheet surface to identify recess portions and gaps between toner images before applying complementing toner. This advance detection enables precise targeting of toner supply only to where it is needed, preventing excessive toner consumption while ensuring adequate filling of gaps to improve fixation performance.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach improves toner fixation performance on embossed sheets by eliminating air layers and ensuring effective heat transfer, reducing toner smudge and transfer, and minimizing the amount of complementing toner required, thus maintaining the sheet's texture and improving printing quality.

Implementation Method 1

supply, to a region where no toner is provided between toner images based on the input image information, complementing toner having a thermal conductivity higher than a thermal conductivity of toner for forming the toner image

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a fixer that fixes a toner image formed on the recording material

Methodology Applied

Scientific EffectThermal energy transfer: Conduction (thermal)

Data Source

PatentUS10222727B2Image forming apparatus which supplies complementing toner to a region between formed toner images in which no toner is provided, and non-transitory computer-readable recording medium storing image forming program

Publication Date: 2019.03.05 KONICA MINOLTA INC

AI summary

An image forming apparatus includes: an image former that forms on a recording material a toner image based on input image information; a fixer that fixes a toner image formed on the recording material; and a hardware processor that controls the image former and the fixer in which the hardware processor controls the image former to supply, to a region where no toner is provided between toner images based on the input image information, complementing toner having a thermal conductivity higher than a thermal conductivity of toner for forming the toner image based on input image information.