Continuous Paper Image Forming Device Toner Refresh Control
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Solution Overview
Problem
In electrophotographic image forming systems, toner refreshing on continuous paper often results in unexpected blank portions and reduced productivity, especially when applying refresh bands to continuous paper, as existing methods do not accurately determine the necessity of creating image patterns based on image coverage, leading to unnecessary job cancellations.
Innovation Solution
An image forming device and program that include an image forming unit, an image pattern creation unit, a determination unit, and a calculation unit to assess the necessity of creating a refresh band based on image coverage and calculate the optimal conveyance distance or time for toner consumption, thereby minimizing blank portions and maintaining productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a refresh band is created whenever the upper limit value is reached, then toner refreshing is ensured, but blank portions are generated on continuous paper and productivity is lowered
Solution Approach 1:
The patent changes the parameter for determining refresh band creation from a fixed paper passing distance (upper limit value) to a dynamic parameter based on cumulative image coverage. The determination unit calculates whether the sum of image coverages since the last refresh band exceeds a threshold, and only creates a refresh band when this condition is met. This parameter change allows the system to adapt to varying image content and avoid unnecessary interruptions, thereby maintaining productivity while ensuring reliable toner refreshing when actually needed.
2Quantity of substance
If a refresh band is created at an unexpected portion between images, then toner is consumed, but the location is not preferable and may cause blank portions
Solution Approach 1:
The patent implements a feedback mechanism where the determination unit continuously monitors the cumulative image coverage since the last refresh band creation. This feedback information is used to intelligently determine the necessity and timing of creating a refresh band. By basing the decision on actual image coverage data rather than fixed distance, the system ensures toner is consumed effectively while minimizing the creation of unwanted blank portions, thus maintaining both toner consumption efficiency and image quality.
3Productivity
If the paper passing distance is limited to a fixed upper limit value, then refresh bands can be created collectively, but jobs with low coverage may complete without needing refresh bands
Solution Approach 1:
The patent replaces the fixed upper limit value parameter with a dynamic determination based on cumulative image coverage. The determination unit calculates the sum of coverages of images formed since the last refresh band and compares it against a threshold. This parameter change enables the system to accurately identify when toner refreshing is actually needed, avoiding both unnecessary refresh bands in low-coverage jobs and missed refreshing in high-coverage jobs, thereby simultaneously improving productivity and reliability.
Data Source
AI summary
An image forming device includes: an image forming unit configured to form a plurality of images on continuous paper based on a job; an image pattern creation unit configured to interrupt execution of the job and create an image pattern for consuming toner; a determination unit configured to determine necessity of creating the image pattern based on coverages of the images included in the job; and a calculation unit configured to, when the determination unit determines that it is necessary to create the image pattern, calculate a conveyance distance or a conveyance time of the continuous paper until creation of the image pattern, as interruption timing.