Image Forming Apparatus Foreign Matter Detection Toner Layer
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Solution Overview
Problem
Existing image forming apparatuses face issues with foreign matters such as adhesives and cutting waste from paper ends being transferred to transfer units, leading to wear and failure of components like intermediate transfer belts.
Innovation Solution
An image forming apparatus equipped with a foreign matter detection unit and a toner layer forming unit that detects and forms a toner layer on the image carrying member to prevent foreign matters from adhering to transfer units, using optical sensors and rotating members to accurately assess and respond to the presence of adhesives or waste at paper ends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate external additive is supplied to prevent adhesive attachment to photoreceptor, then adhesive transfer is reduced, but the amount of protective particles is small and prevention effect is insufficient
Solution Approach 1:
The patent introduces a toner layer as an intermediary substance between the adhesive and the photoreceptor/intermediate transfer belt. This toner layer acts as a sacrificial barrier that the adhesive attaches to instead of the expensive photoreceptor or intermediate transfer belt, thereby protecting these components while using a controlled amount of toner material.
Solution Approach 2:
The patent employs toner particles as a disposable protective layer. Instead of trying to prevent adhesive attachment through small amounts of durable external additive, the system creates a temporary toner layer that absorbs the adhesive's attachment tendency. This toner layer is subsequently removed in the cleaning process, effectively sacrificing a cheap material to protect expensive components.
2Reliability
If foreign matter is detected at paper end portion, then protective toner layer can be formed, but requires additional detection unit and control complexity
Solution Approach 1:
The patent implements preliminary detection of foreign matter at the paper end portion using an optical sensor before the paper reaches the transfer unit. Based on this advance detection, the system proactively forms a protective toner layer on the intermediate transfer belt in advance, preventing foreign matter transfer before it occurs rather than reacting after damage happens.
Solution Approach 2:
The patent establishes a feedback control loop where the optical sensor continuously monitors the paper end portion for foreign matter, and the control unit adjusts the toner layer formation accordingly. When foreign matter is detected, the system activates the toner layer formation; when no foreign matter is present, the system returns to normal operation, creating a responsive adaptive protection mechanism.
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
Effectively prevents foreign matters from adhering to transfer units, reducing wear and failure, while minimizing toner consumption and maintaining image quality.
Implementation Method 1
a foreign matter detection unit for detecting a foreign matter projecting from an end portion of the paper
Implementation Method 2
a toner layer forming unit for forming a toner layer on a surface of the image carrying member
Data Source
AI summary
An image forming apparatus of the present invention includes an image carrying member capable of carrying an image, a paper conveying unit, a foreign matter detection unit, and a toner layer forming unit. The paper conveying unit conveys a paper to the image carrying member. The foreign matter detection unit detects a foreign matter projecting from the end portion of the paper. The toner layer forming unit forms a toner layer on the surface of the image carrying member in response to a position of the foreign matter detected by the foreign matter detection unit.