Feeder Image Toner Gradient for Cleaning Blade Lubrication
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Solution Overview
Problem
Existing image forming apparatuses face challenges in maintaining effective lubrication of cleaning members, leading to reduced cleaning performance and potential image quality issues due to sudden changes in toner density and distribution, which affects productivity and developer consumption.
Innovation Solution
An image forming apparatus that includes a controller forming a feeder image with toner density varying along its travel direction, where the upstream side has a lower density and the downstream side has a higher density, ensuring consistent lubrication and efficient developer distribution to prevent premature developer passage and optimize cleaning performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a highly dense image is formed first for lubrication of the cleaning member, then the cleaning member is adequately lubricated, but productivity is reduced due to the sequential process requirement
Solution Approach 1:
The patent combines the lubrication function and image formation function into a single integrated process. The feeder image is formed in the same operational sequence as normal image formation, eliminating the need for separate lubrication passes. This merging allows the cleaning member to be lubricated by the feeder image toner while simultaneously forming useful images, thereby maintaining productivity while ensuring adequate lubrication.
Solution Approach 2:
The feeder image is formed in advance within the normal image formation sequence, providing preliminary lubrication to the cleaning member before it processes subsequent images. This preliminary action ensures the cleaning member is properly lubricated from the start, preventing issues like cleaning blade rolling up and ensuring consistent cleaning performance throughout operation.
2Reliability
If toner is fed with high density to the cleaning blade earlier, then the cleaning blade is well-lubricated, but toner distribution becomes uneven and cleaning performance degrades
Solution Approach 1:
The patent applies local quality by creating a feeder image with spatially varying toner density. The upstream side of the feeder image has higher toner density to provide adequate lubrication to the cleaning blade as it first contacts the toner. The downstream side has lower toner density to ensure uniform toner distribution and prevent excessive toner accumulation. This gradient density approach ensures both proper lubrication and uniform toner distribution across the cleaning blade surface.
3Reliability
If linear toner feed lines are drawn with high density in end portions and low density in center portion, then the cleaning blade is lubricated, but the process complexity increases
Solution Approach 1:
The feeder image serves multiple functions simultaneously: it lubricates the cleaning blade, provides uniform toner distribution, and can be integrated with normal image formation processes. By designing the feeder image with appropriate toner density gradients, the system achieves lubrication without requiring separate lubrication mechanisms or complex additional processes, thereby maintaining system simplicity while ensuring reliable cleaning blade maintenance.
Data Source
AI summary
An image forming apparatus includes an image carrier, a cleaner, and a controller. The image carrier holds an image on a surface thereof. The cleaner cleans the surface of the image carrier. The controller forms, at timing at which a developer is fed to the cleaner, a feeder image that feeds the developer to the cleaner. The feeder image includes toner whose amount is smaller on a downstream side than on an upstream side in a travel direction of the image carrier.