Multilayer Toner Transfer Control for Transparent Media Edge Defects

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Solution Overview

Problem

Existing image forming apparatuses fail to address the scattering of toner from the lowermost layer of a multilayer toner image, particularly when forming images on transparent media, leading to unintended image edges due to white toner scattering outside the intended pattern.

Innovation Solution

An image forming apparatus that performs specific control to reduce the volume of the lowermost toner layer by a predetermined number of pixels relative to the upper toner layer, generating an image signal to minimize toner scattering during transfer onto a recording medium.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the area of the lowermost toner layer is reduced to prevent scattering, then image quality improves, but the coverage and opacity of the toner layer deteriorate

Engineering Contradiction:

Improveimage qualityVSAvoidtoner layer coverage

Core Design Contradiction:

Manufacturing precisionVSArea of stationary object

Solution Approach 1:

The patent applies local quality by differentiating the area of the lowermost toner layer based on its position relative to other toner layers. Specifically, the area of the lowermost toner layer is reduced only in regions where it overlaps with upper toner layers of the same color pattern, while maintaining full coverage in non-overlapping regions. This localized adjustment prevents scattering at critical interfaces without sacrificing overall coverage and opacity.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If the area of the lowermost toner layer is reduced to prevent scattering, then image integrity improves, but the volume of toner material increases

Engineering Contradiction:

Improveimage integrityVSAvoidtoner material volume

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The patent implements local quality by selectively reducing the area of the lowermost toner layer only in specific overlapping regions where scattering occurs, rather than uniformly reducing the entire layer. This targeted approach minimizes the volume of toner material removed while maintaining image integrity at critical interfaces, thereby optimizing the balance between preventing scattering and conserving toner material.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If the area of the lowermost toner layer is reduced to prevent scattering, then image clarity improves, but the transfer efficiency deteriorates

Engineering Contradiction:

Improveimage clarityVSAvoidtransfer efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent applies local quality by reducing the area of the lowermost toner layer only in regions where it overlaps with upper toner layers of the same color pattern, while maintaining full area in non-overlapping regions. This localized adjustment ensures that transfer efficiency is maintained in non-overlapping regions while improving image clarity in overlapping regions where scattering would otherwise occur.

Inventive Principle:

Principle #3Local quality

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

Reduces the influence of toner scattering on the formed image by minimizing the area of the lowermost toner layer, preventing unintended image edges and maintaining image integrity, especially on transparent films.

Implementation Method 1

forms an electrostatic latent image by exposing a charged photoreceptor with toner

Methodology Applied

Scientific EffectPhotoelectric Effect: Photoelectric Effect

Implementation Method 2

develops an electrostatic latent image formed by exposing a charged photoreceptor with toner

Methodology Applied

Scientific EffectElectrostatic Attraction: Electrostatics

Implementation Method 3

transfers the toner image to an intermediate transfer member

Methodology Applied

Scientific EffectElectrostatic Transfer: Electrostatics

Implementation Method 4

performs fixing processing for heating and pressurizing the toner image on the recording medium to fix the toner image

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS20260003300A1Image forming apparatus, control method, and recording medium storing control program

Publication Date: 2026.01.01 KONICA MINOLTA INC

AI summary

An image forming apparatus that forms a toner image by superimposing toner layers on an intermediate transfer member and transfers the formed toner image onto a recording medium, the image forming apparatus including a hardware processor that performs specific control for reducing, relative to a volume of a single-layer toner image to be transferred onto the recording medium when the single-layer toner image including a single-color toner layer is formed, a volume of a lowermost toner layer with a color same as a color of the single-color toner layer in a multilayer toner image to be transferred onto the recording medium when the multilayer toner image is formed by superimposing toner layers of a plurality of colors having a pattern same as a pattern of the single-layer toner image.