Toner Amount Calculation Using Particle Size Distribution Data
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Solution Overview
Problem
Conventional image forming apparatuses face challenges in accurately determining toner amounts due to changes in toner particle size distribution over time, especially in process-cartridge type developing units, leading to errors in image density and tone reproduction.
Innovation Solution
An image forming apparatus that includes a photosensor to detect toner areas, an information obtaining unit to track particle-size-change information, and a toner-amount calculating unit to calculate accurate toner amounts based on detected toner areas and particle-size-change information, using a cross-reference table to correct for varying particle sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If toner amount is calculated based on photosensor detection assuming specific particle size distribution, then calculation is simple, but accuracy deteriorates when actual particle size distribution differs
Solution Approach 1:
The patent changes the parameter used for toner amount calculation from assuming a specific particle size distribution to using actual particle size distribution information. The toner amount calculating unit obtains particle size distribution information and uses this dynamic parameter to accurately calculate toner amount regardless of how the distribution changes over time during selective development.
2Device complexity
If process-cartridge type developing unit is used, then device structure is simple, but toner amount measurement accuracy deteriorates due to particle size distribution change over time
Solution Approach 1:
The patent introduces a feedback mechanism where particle size distribution information is continuously obtained and fed back to the toner amount calculating unit. This allows the system to compensate for changes in particle size distribution that occur during selective development in process-cartridge type developing units, maintaining accurate toner amount measurement throughout the cartridge's usage life.
3Manufacturing precision
If selective development is implemented, then image quality is improved, but particle size distribution changes over time causing measurement errors
Solution Approach 1:
The patent makes the toner amount calculation dynamic by continuously obtaining updated particle size distribution information. Instead of using a fixed assumption about particle size distribution, the system adapts to the changing distribution caused by selective development, allowing accurate toner amount measurement throughout the entire development process.
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
Enables accurate toner amount calculation and maintains image density and tone reproduction even as toner particle size distribution changes, improving the reliability of image formation in systems with varying toner particle sizes.
Implementation Method 1
a photosensor that configured to detect a toner area where the toner is sticking to the image carrier form the toner image
Data Source
AI summary
An image forming apparatus includes an image carrier, a toner-image forming unit, a photosensor, an information obtaining unit, and a toner-amount calculating unit. The toner-image forming unit forms a toner image on the image carrier with toner. The photosensor detects a toner area where the toner is sticking to the image carrier. The information obtaining unit obtains particle-size-change information about how particle size distribution of the toner changes over time. The toner-amount calculating unit calculates a toner amount of the toner image based on the toner area and the particle-size-change information.