Image Forming Apparatus Residual Toner Overflow Control
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Solution Overview
Problem
In image forming apparatuses, the residual toner collecting container often overflows during continuous printing due to limited capacity, leading to decreased productivity and increased wear on the image forming mechanism, especially when the residual toner feeding screw shares a driving source with the image forming mechanism.
Innovation Solution
An image forming apparatus with a control unit that adjusts the driving speed of the developer feeding unit based on the residual developer amount in the collecting container between print jobs, optimizing the sheet interval to prevent overflow while minimizing the lifetime consumption of the image forming mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the residual toner feeding screw is driven by the same driving source as the image forming mechanism, then the device complexity is reduced and manufacturing cost is lowered, but the lifetime of the image forming mechanism is consumed faster
Solution Approach 1:
The patent applies dynamics by making the driving source configurable - it can operate in a first mode where one driving source drives both the image forming mechanism and residual toner feeding screw, and a second mode where separate driving sources are used. This dynamic reconfiguration allows the system to adapt between cost-reduced and lifetime-protected operating states based on operational needs.
2Reliability
If the sheet interval is extended to prevent residual toner overflow in the collecting container, then the overflow problem is solved, but the productivity of printing is reduced
Solution Approach 1:
The patent implements feedback control by monitoring the residual toner amount in the collecting container and using this information to dynamically adjust the sheet interval. The control unit receives information about the residual toner amount and determines the appropriate sheet interval based on this feedback, preventing overflow while optimizing productivity.
Solution Approach 2:
The patent applies preliminary action by proactively controlling the residual toner feeding screw to transfer toner from the collecting container to the storing container before the container becomes full. This preventive approach allows the system to maintain shorter sheet intervals without risking overflow, thereby preserving productivity.
3Reliability
If the residual toner feeding amount is increased to prevent overflow, then the overflow problem is solved, but the lifetime of the image forming mechanism is consumed faster
Solution Approach 1:
The patent applies dynamics by enabling flexible configuration of the driving source operation modes. In the first mode, the system increases residual toner feeding amount to prevent overflow. In the second mode, separate driving sources are used, allowing high feeding amounts without consuming the image forming mechanism lifetime, thus adapting to different operational requirements.
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 solution effectively prevents residual toner overflow while maintaining productivity and extending the lifespan of the image forming mechanism by dynamically adjusting the driving speed of the developer feeding unit according to the residual toner amount.
Implementation Method 1
a driving unit configured to drive the developer feeding unit and at least one of the image bearing member, the developing unit and the transfer unit
Data Source
AI summary
An image forming apparatus includes an image bearing member, a charging unit, a developing unit, a transfer unit, a residual developer collecting container, a developer feeding unit, a driving unit configured to drive the developer feeding unit and at least one of the image bearing member, the developing unit and the transfer unit, and a control unit configured to change a driving speed of the driving unit depending on a storing amount of the residual developer in the collecting container in a period from an end of formation of an image on a first recording material to a start of formation of the image on a second recording material subsequent to the first recording material.