Photoreceptor Contact State Detection in Image Forming Apparatus
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Solution Overview
Problem
Existing image forming apparatuses face challenges in efficiently determining the contact state between a photoreceptor and a charging roller, as well as between the photoreceptor and a transfer section, which can lead to improper charging and image transfer, resulting in wasteful toner consumption and contamination.
Innovation Solution
The image forming apparatus includes a controller that performs predetermined determination processing at startup to assess both the contact state between the photoreceptor and the charging roller and the contact state between the photoreceptor and the transfer section. This is achieved by using a toner concentration sensor to detect the concentration of a patch toner image with a striped pattern, allowing for accurate determination of contact states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separation mechanism is provided to separate the photoreceptor and charging roller before shipment, then the photoreceptor is protected from physical or chemical damage, but the device complexity increases and the contact state determination becomes more difficult
Solution Approach 1:
A separator member is introduced as an intermediary component between the photoreceptor and charging roller. This separator brings them into contact through a separator contact portion, enabling indirect contact that protects the photoreceptor while allowing charging function. The separator acts as a mediator that resolves the contradiction between protection and functionality.
Solution Approach 2:
The contact mechanism is segmented into distinct functional portions: a separator contact portion for charging and a non-contact portion for protection. This segmentation allows the system to provide both protection and charging functionality through different segments of the same component structure.
2Productivity
If the charging roller is continuously pressed in contact with the photoreceptor, then charging function is maintained, but the photoreceptor surface is physically or chemically damaged
Solution Approach 1:
The separator contact portion serves as an intermediary between the charging roller and photoreceptor surface, enabling charge transfer while preventing direct mechanical contact that would cause damage. This mediator approach maintains productivity while eliminating harmful effects.
Solution Approach 2:
Different portions of the separator have different functional qualities: the separator contact portion enables charging interaction while the non-contact portion provides protection. This local differentiation of quality allows simultaneous achievement of charging function and damage prevention.
3Loss of substance
If a separate state determination device is added to detect contact state, then toner consumption waste is reduced, but the device complexity increases
Solution Approach 1:
The separator structure serves multiple functions simultaneously: it enables charging through the separator contact portion, protects the photoreceptor through the non-contact portion, and provides a built-in mechanism for determining contact state. This multi-functionality reduces the need for additional separate determination devices.
Solution Approach 2:
The separator's own structure and position provide the determination information needed. The presence or absence of contact between the separator contact portion and photoreceptor surface inherently indicates the contact state, allowing the system to self-determine its state without external sensing devices.
4Productivity
If the canceling mechanism is provided to bring the charging roller into contact with the photoreceptor at startup, then charging is enabled, but malfunction may cause the photoreceptor to remain uncharged leading to wasteful toner consumption
Solution Approach 1:
The separator contact portion acts as a reliable intermediary that ensures contact is established through the separator rather than direct roller-to-photoreceptor contact. This mediator approach provides more reliable and controllable contact establishment compared to direct canceling mechanisms.
Solution Approach 2:
The system can detect whether the separator contact portion is in contact with the photoreceptor surface and use this feedback information to determine if charging is properly enabled. This feedback mechanism allows the system to verify the contact state and take appropriate actions, improving reliability.
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
The apparatus can efficiently determine contact states between the photoreceptor and both the charging roller and the transfer section, preventing wasteful toner consumption and contamination, and ensuring proper image formation.
Implementation Method 1
a toner concentration sensor that detects concentration of the toner image transferred to the transfer section
Data Source
AI summary
An image forming apparatus includes: an image forming section; and one or more controllers that control the image forming section. At the time of start-up of the image forming section, the one or more controllers perform predetermined determination processing by which both a contact state between a photoreceptor and a transfer section and a contact state between the photoreceptor and a charging section are determined, when determining that the photoreceptor is in the contact state with the transfer section and the photoreceptor is in the contact state with the charging section, the one or more controllers determine normality, and when determining that the photoreceptor is not in the contact state with the transfer section or the photoreceptor is not in the contact state with the charging section, the one or more controllers determine that abnormality has occurred and limit operation of the image forming section to a predetermined operation.