Image Forming Apparatus Secondary Transfer Roller Voltage Control

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

The existing image forming apparatuses face challenges in managing high transfer voltages near the apparatus body's side face, leading to potential electric discharge and complicating the wiring structure due to limited space, especially when securing a creepage distance between the frame and the secondary transfer roller.

Innovation Solution

The apparatus incorporates a current feeder connected to the first belt support roller, a current sensor, and a rectifier to control the secondary transfer current, ensuring a constant current value by subtracting the leak current from the output current and maintaining the voltage on the secondary transfer roller below a predetermined reference voltage, thereby preventing electric discharge and simplifying the wiring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the secondary transfer roller is placed near the apparatus body's side face for compact design, then the device complexity is reduced, but the reliability deteriorates due to potential electric discharge from high transfer voltage

Engineering Contradiction:
Improvewiring structure complexityVSAvoidelectric discharge prevention
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The patent introduces an intermediary insulating structure (insulating layer or insulating barrier) between the secondary transfer roller and the apparatus body frame. This mediator prevents direct electrical contact and discharge paths while allowing the compact placement to remain effective.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent increases the creepage distance by utilizing the vertical dimension (thickness direction of the apparatus body) rather than only the horizontal plane. By placing the secondary transfer roller at a position where vertical clearance is available, the design achieves adequate insulation without increasing the horizontal footprint or complicating wiring routes.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Reliability

If the creepage distance is increased to prevent electric discharge, then the reliability is improved, but the device complexity worsens due to complicated wiring requirements

Engineering Contradiction:
Improveelectric discharge preventionVSAvoidwiring structure complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The insulating structure serves as a mediator that provides the necessary creepage distance without requiring complex wiring routes. Instead of routing wires through lengthy paths to achieve insulation, the insulating barrier directly provides the separation, simplifying the wiring design.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent segments the apparatus body structure to create dedicated insulating zones around high-voltage components. By dividing the structure into conductive and insulating regions, the design achieves adequate creepage distance without requiring continuous complex wiring insulation throughout the entire path.

Inventive Principle:
Principle #1Segmentation

3Reliability

If the secondary transfer roller is connected to ground to prevent electric discharge, then the reliability is improved, but the device complexity worsens due to additional wiring and control requirements

Engineering Contradiction:
Improveelectric discharge preventionVSAvoidcontrol system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

Instead of directly connecting the secondary transfer roller to ground, the patent uses an insulating intermediary structure. This approach prevents discharge paths without requiring active ground connections, control circuits, or additional wiring to manage grounding potentials.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the electrical grounding system with a physical/structural insulating barrier. Rather than using electrical connections (grounding wires, grounding clips) to prevent discharge, the solution uses the mechanical/physical presence of insulating material to block discharge paths, eliminating the need for complex electrical control systems.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

4Device complexity

If the transfer voltage is applied close to the apparatus body to simplify wiring, then the device complexity is reduced, but the reliability deteriorates due to increased risk of electric discharge

Engineering Contradiction:
Improvewiring structure complexityVSAvoidelectric discharge prevention
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The insulating structure acts as a mediator that enables close placement of the high-voltage component while maintaining safety. The intermediary layer allows the secondary transfer roller to be positioned near the apparatus body without creating direct discharge paths, thus maintaining both simplicity and reliability.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the electrical parameters by controlling the voltage level and current characteristics to operate within safe limits. By adjusting the transfer voltage and ensuring it remains below discharge thresholds, the system can safely operate with reduced creepage distances while maintaining reliability.

Inventive Principle:
Principle #35Parameter changes

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 configuration effectively suppresses the drop in secondary transfer current and prevents electric discharge, ensuring reliable image transfer and simplifying the structural complexity of wiring, even when a leak current occurs, thus maintaining image quality and apparatus reliability.

Implementation Method 1

The rectifier is electrically connected between the second belt support roller and the ground, shuts off a current passing from the second belt support roller to the ground if the voltage on the second belt support roller is less than a predetermined reference voltage, and permits the leak current to pass from the second belt support roller to the ground if the voltage on the second belt support roller is equal to or more than the reference voltage

Methodology Applied
Scientific EffectRectification: Diode

Implementation Method 2

The current sensor has a lead member electrically connecting between the current feeder and the second belt support roller, and senses a leak current passing from the first belt support roller via the intermediate transfer belt to the second belt support roller

Methodology Applied
Scientific EffectElectrical Conduction: Conduction (electrical)

Implementation Method 3

The primary transfer roller makes contact with the inner circumferential surface of the intermediate transfer belt, and is disposed opposite the image carrying member across the intermediate transfer belt. Applying a primary transfer voltage with the opposite polarity to toner permits the toner image carried on the image carrying member to be primarily transferred to the intermediate transfer belt

Methodology Applied
Scientific EffectElectrostatic Transfer: Electrostatics

Implementation Method 4

The secondary transfer roller is fed with a secondary transfer current to secondarily transfer the toner image transferred to the intermediate transfer belt on to a sheet passing between the secondary transfer roller and the intermediate transfer belt

Methodology Applied
Scientific EffectElectrostatic Transfer: Electrostatics

Data Source

PatentUS12078950B2Image forming apparatus
Publication Date: 2024.09.03 KYOCERA DOCUMENT SOLUTIONS INC
  • US12078950B2 patent drawing
  • US12078950B2 patent drawing
  • US12078950B2 patent drawing

AI summary

An image forming apparatus includes an image carrying member, an intermediate transfer belt, a primary transfer roller, a first belt support roller, a secondary transfer roller, a second belt support roller, a current feeder, a controller, a current sensor, and a rectifier. The current sensor has a lead member. The rectifier shuts off a current passing from the second belt support roller to the ground if the voltage on the second belt support roller is less than a predetermined reference voltage. The controller controls the output current such that the secondary transfer current has a current value resulting from subtracting a leak current from the output current and, when the lead member is in a conducting state, keeps the voltage on the second belt support roller less than the reference voltage.