Image Former Coverage Calculation for Toner Preservation
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Solution Overview
Problem
Image forming apparatuses face issues with toner deterioration and wasteful consumption when printing low-coverage images on continuous paper, as existing solutions either consume excess toner or narrow printable regions, and users are not informed about the optimal printing distance to avoid generating waste paper.
Innovation Solution
An image forming apparatus that calculates the coverage of printed images and informs the user of the continuously printable distance without forming toner-ejection patterns, allowing for user-friendly continuous printing without toner wastage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If image patterns are formed in side regions outside the image region to eject toner, then toner deterioration is prevented, but the printable regions become narrow and toner is wastefully consumed
Solution Approach 1:
The patent transitions from using side regions (2D space outside image area) to using the time dimension by forming image patterns on the intermediate transfer belt between sheets. This allows toner ejection without consuming printable region area, resolving the contradiction between preventing toner deterioration and maintaining printable region size
Solution Approach 2:
The patent forms image patterns on the intermediate transfer belt continuously between sheets during normal operation, rather than stopping the job or using side regions. This maintains continuous useful printing action while preventing toner deterioration through periodic ejection
2Reliability
If image patterns are formed to eject toner when printing low coverage images, then toner deterioration is prevented, but toner is wastefully consumed
Solution Approach 1:
The patent calculates coverage based on image information and uses this feedback to determine when image patterns should be formed. By monitoring coverage metrics, the system forms ejection patterns only when necessary (low coverage conditions), preventing toner deterioration while avoiding wasteful consumption during high coverage printing
Solution Approach 2:
The patent changes the parameter of image pattern formation from being based on printing distance (fixed threshold) to being based on coverage calculation (dynamic parameter). This allows adaptive control that prevents toner deterioration when needed while reducing wasteful consumption when coverage is high
3Reliability
If the job is stopped to form image patterns for ejecting toner, then toner deterioration is prevented and wasteful consumption is reduced, but waste paper is generated and users cannot grasp the printing distance
Solution Approach 1:
The patent calculates coverage in advance based on image information before printing begins and determines the continuously printable distance beforehand. This allows users to know the printing distance limit in advance without experiencing unexpected job stops or waste paper generation
Solution Approach 2:
The patent replaces the mechanical approach of stopping the job and generating waste paper with an information-based approach. The controller calculates coverage and informs users of the continuously printable distance, substituting physical waste paper generation with digital information provision
4Reliability
If image patterns are formed based on a predetermined distance threshold, then toner ejection is ensured, but toner is wastefully consumed when high coverage images are printed
Solution Approach 1:
The patent changes the control parameter from fixed printing distance to dynamic coverage calculation. By using coverage as the decision parameter, the system ensures toner ejection when necessary (low coverage) while avoiding wasteful consumption when high coverage images are printed, regardless of printing distance
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
Enables continuous printing on continuous paper without toner deterioration and wasteful consumption, while providing users with the knowledge of the printable distance, enhancing usability by allowing adjustments to extend the printing distance when necessary.
Implementation Method 1
forming an electrostatic latent image on an image holder based on image information of a job
Implementation Method 2
developing the electrostatic latent image with toner, thereby forming a toner image on the image holder
Data Source
AI summary
An image forming apparatus includes an image former, an informing unit, and a hardware processor. The image former prints an image on continuous paper by: forming an electrostatic latent image on an image holder based on image information of a job; developing the electrostatic latent image with toner, thereby forming a toner image on the image holder; and transferring the toner image onto the continuous paper. Based on the image information of the job, the hardware processor calculates a coverage of the image to be printed on the continuous paper. Based on the calculated coverage, the hardware processor determines a continuously printable distance on the continuous paper. The hardware processor causes the informing unit to inform a user of the continuously printable distance before the image former starts the printing.