Transfer Device With Dynamic Nip Switching for Toner Conservation
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Solution Overview
Problem
Existing image forming apparatuses with transfer devices for special colors like transparent or white toner suffer from excessive toner consumption due to the configuration where the transfer roller is separated from the photoconductor when no toner image is formed, leading to inefficiencies and waste.
Innovation Solution
A transfer device with multiple primary transfer sections, a tension roller, and movement mechanisms that allow the tension roller and primary transferors to move between contact and separation positions, optimizing the position of the intermediate transferor and preventing unnecessary toner consumption by selectively forming transfer nips only when needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the transfer roller is separated from the photoconductor when no toner image is formed, then excessive toner consumption is prevented, but the device complexity increases due to the need for movement mechanisms
Solution Approach 1:
The patent implements dynamic separation and contact mechanisms that allow the transfer roller and primary transferors to move between separated and contacted states based on whether toner image formation is required. This dynamic configuration enables the system to switch between toner-saving mode (separated) and transfer mode (contacted), resolving the contradiction between preventing toner consumption and maintaining operational functionality.
Solution Approach 2:
The system employs periodic switching between separation and contact states of the transfer roller and primary transferors. The movement mechanisms periodically adjust the positions of these components based on the presence or absence of toner image formation requirements, creating a rhythmic pattern of engagement and disengagement that optimizes both toner efficiency and device functionality.
2Stability of the object's composition
If the tension roller is positioned to stretch the intermediate transferor, then the intermediate transferor maintains proper tension, but the position adjustment complexity increases with multiple movement mechanisms
Solution Approach 1:
The patent combines the tensioning function and the separation/contact function into a single integrated movement mechanism system. The first movement mechanism simultaneously controls both the tension roller position for stretching the intermediate transferor and the separation/contact state of the transfer roller, reducing the overall complexity by merging multiple functions into unified control structures.
Solution Approach 2:
The movement mechanisms are designed with multi-functionality, where the same mechanism serves multiple purposes: adjusting tension roller position for intermediate transferor stretching, controlling transfer roller separation from photoconductor, and positioning primary transferors relative to the intermediate transferor. This universal design reduces the total number of separate mechanisms needed.
Data Source
AI summary
A transfer device includes an intermediate transferor to rotate, primary transfer sections, a tension roller, a first movement mechanism, and a second movement mechanism. Each of the primary transfer sections includes a primary transferor. The tension roller stretches the intermediate transferor. The first movement mechanism causes the tension roller to move and change a position at which the tension roller stretches the intermediate transferor. The second movement mechanism causes the primary transferor of a primary transfer section to move to a contact position at which the primary transferor contacts a latent image bearer and a separation position at which the primary transferor is separated from the latent image bearer. The most-downstream primary transferor is movable between a contact position and a separation position. The first movement mechanism causes the tension roller to move to at least three positions at each of which the tension roller stretches the intermediate transferor.