Optical Sensor Calibration for Thin-Film Image Support
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Solution Overview
Problem
In electrophotographic image-forming apparatuses, the use of intermediate transfer members with thin-film layers leads to optical interference and inaccurate image-stabilizing control due to reflectance fluctuations, causing defective image formation and failure to maintain image density within predetermined ranges.
Innovation Solution
The image-forming apparatus incorporates an optical sensor with a light source and light-receiving unit that applies and receives light to detect toner patterns on an image-supporting member with a thin-film layer, where the thickness of the outermost surface thin-film layer is set to satisfy a specific reflectance function, minimizing optical interference and ensuring accurate calibration and detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a thin-film layer is formed on the intermediate transfer member to improve toner peeling property, then transferring efficiency is improved, but optical interference occurs causing inaccurate image-stabilizing control
Solution Approach 1:
The patent changes the physical parameter of the thin-film layer by controlling its thickness to be 50 nm or less. This parameter change reduces the optical path difference caused by the film, thereby minimizing optical interference effects while preserving the film's functional benefits for toner transfer.
Solution Approach 2:
The patent creates an optical model that copies the physical situation of light interaction with the thin-film layer. By mathematically modeling the optical path difference and interference patterns, the invention predicts and controls optical interference effects without physically altering the system, enabling accurate image-stabilizing control.
2Productivity
If the intermediate transfer member is driven during detection to enable continuous operation, then productivity is maintained, but optical thickness fluctuates causing conspicuous optical interference
Solution Approach 1:
The patent applies preliminary action by pre-compensating for optical interference effects through calibration. Before actual image formation, the system calibrates the optical sensor readings to account for the optical path differences introduced by the thin-film layer, thereby eliminating interference effects during continuous operation.
Solution Approach 2:
The patent implements feedback control by continuously monitoring image density through the optical sensor and adjusting formation conditions based on detected variations. The system uses the detected optical thickness fluctuations as feedback to dynamically compensate for interference effects, maintaining stable image quality during continuous operation.
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 approach effectively stabilizes image density by restraining optical interference and reflectance fluctuations, enabling precise calibration and detection of toner patterns, thus maintaining image quality and density within predetermined ranges.
Implementation Method 1
an optical sensor that includes a light source unit which applies light having a light-emission main wavelength λ to a peripheral face of an image-supporting member, and a light-receiving unit which receives a reflected light thereof
Implementation Method 2
an optical interference occurs due to influences of optical characteristics between the optical sensor and the thin-film layer
Data Source
AI summary
An image-forming apparatus includes:an optical sensor that includes a light source unit which applies light having a light-emission main wavelength λ to a peripheral face of an image-supporting member, and a light-receiving unit which receives a reflected light thereof, so as to optically detect a toner pattern formed on a peripheral face of the image-supporting member, wherein the image-supporting member has at least one thin-film layer formed on the peripheral face thereof, and the thickness of an outermost surface thin-film layer is set so as to allow a reflectance function R(d) that indicates the relationship between a reflectance R of the peripheral face of the image-supporting member to light having a light-emission main wavelength λ from the light source unit and a thickness d (nm) of the outermost surface thin-film layer of the image-supporting member to satisfy:R(d)≧0.75×{Rmax(d)−Rmin(d)}+Rmin(d).