Image Forming Apparatus with Independent Toner Density Control
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Solution Overview
Problem
Conventional image forming apparatuses using thermocompression bonding methods face challenges when the user sets low toner density for the product, resulting in insufficient adhesive force due to low toner density at the pressing position.
Innovation Solution
The apparatus includes a process cartridge with a recording material, an image former that forms separate images for the body and adhesion, and a sheet bonder that bonds sheets based on individually controlled image densities set by the user.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the user sets low toner density for the product, then the image quality is improved, but the adhesive force becomes insufficient
Solution Approach 1:
The patent applies different toner density settings to different regions of the sheet. The image regions use the user-set low toner density for quality, while the pressing position regions use high toner density for adhesion. This local differentiation resolves the contradiction by allowing low overall density while maintaining high adhesive force where needed.
Solution Approach 2:
The patent segments the toner image into two distinct parts: image-forming regions and pressing position regions. By controlling these segments independently with different density levels, the system achieves both low image density for quality and high pressing position density for adhesive force.
2Strength
If the user sets high toner density for the product, then the adhesive force is improved, but the image quality deteriorates
Solution Approach 1:
The patent applies high toner density only to the pressing position regions where adhesion is needed, while keeping the image regions at the user-set density level. This localized application of high density improves adhesive force without degrading overall image quality.
Solution Approach 2:
The patent segments the sheet into image regions and pressing position regions, applying different toner densities to each segment. This allows high density at pressing positions for adhesion while maintaining appropriate density in image regions for quality.
3Ease of operation
If a single toner density setting is applied to the entire image, then the operation is simplified, but the adhesive force cannot be controlled independently
Solution Approach 1:
The system automatically controls the toner density at pressing positions based on the user's image density setting. The control unit independently adjusts the pressing position density without requiring separate user input, making the operation simple while achieving adhesive force control.
Solution Approach 2:
The control unit receives the user's image density setting as input and automatically determines the appropriate pressing position density. This feedback mechanism allows independent adhesive force control while maintaining ease of operation through automatic adjustment.
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 allows for precise control of image densities, ensuring an adequate adhesive force even at low toner density settings, thereby effectively bonding sheets together.
Implementation Method 1
an image former configured to form a first image for a body and a second image for adhesion on a sheet by using a recording material
Implementation Method 2
Japanese Patent Laid-Open No. 2004-209859 proposes a technique for using thermocompression to bond sheets coated with toner as an adhesive material to each other by applying heat and pressure
Data Source
AI summary
Disclosed is an image forming apparatus that includes a process cartridge including a recording material; an image former that form a first image for a body and a second image for adhesion on a sheet by using a recording material; a sheet bonder that bond together a predetermined number of sheets on which at least one image has been formed; one or more memory devices that store a set of instructions; and one or more processors that execute the set of instructions to: set a density level of an image to be formed, and based on the set density level, individually control densities of the first image and the second image.