Transfer Residual Toner Detection in Image Forming Apparatus

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Solution Overview

Problem

In existing image forming apparatus, the amount or presence of transfer residual toner discharged during a single discharge operation of the photosensitive member cleaner is not determinable, leading to uncertainties in toner deterioration and storage levels.

Innovation Solution

An image forming apparatus comprising a conveyor member, a process unit, and a controller, where the process unit includes a photosensitive member, an image forming portion, a transfer member, and a catching portion to catch and return transfer residual developer, allowing the controller to determine its presence or amount using a sensor, and adjust image formation criteria accordingly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the photosensitive member cleaner temporarily catches transfer residual toner and the belt cleaner collects it, then transfer residual toner is removed from the photosensitive member, but the amount or presence of transfer residual toner discharged during a single discharge operation cannot be determined

Engineering Contradiction:

Improvetransfer residual toner removalVSAvoidtransfer residual toner amount detection

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent introduces a feedback mechanism where the controller detects transfer residual toner on the conveyor member using a sensor and uses this information to determine the discharge state of the photosensitive member cleaner. This feedback loop enables accurate measurement of transfer residual toner amount while maintaining reliable removal functionality.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The conveyor member acts as an intermediary carrier between the photosensitive member and the waste toner collection system. By detecting toner on the conveyor member rather than directly on the photosensitive member or in the collection container, the system achieves non-contact measurement of transfer residual toner amount discharged during each operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If no sensor is used to detect transfer residual toner, then the device complexity is low, but the amount or presence of transfer residual toner cannot be determined

Engineering Contradiction:

Improvedetection systemVSAvoidtransfer residual toner information

Core Design Contradiction:

Device complexityVSLoss of information

Solution Approach 1:

The existing sensor system in the image forming apparatus is utilized for dual purposes: both for normal operation monitoring and for detecting transfer residual toner on the conveyor member. This approach avoids adding separate detection hardware while still enabling accurate measurement of transfer residual toner amount and presence.

Inventive Principle:

Principle #25Self-service

3Device complexity

If transfer residual toner is not returned to the photosensitive member, then the catching portion structure is simple, but the toner cannot be reused and image quality may be affected

Engineering Contradiction:

Improvecatching portion structureVSAvoidtoner utilization rate

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent implements a recovering mechanism where the catching portion returns detected transfer residual toner to the photosensitive member for reuse. This prevents toner waste and maintains image quality by ensuring sufficient developer availability, while the controller manages the return timing based on discharge state detection.

Inventive Principle:

Principle #34Discarding and recovering

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 determination of transfer residual toner levels, allowing for timely maintenance, improved image quality, and optimized toner usage by adjusting image formation criteria based on toner deterioration, thereby reducing image degradation and notifying users of toner storage levels.

Implementation Method 1

The controller may be configured to determine whether the transfer residual developer is present or absent on a surface of the conveyor member using a sensor

Methodology Applied

Scientific EffectSensor detection:

Data Source

PatentUS8792795B2Image forming apparatus that forms and senses marks and method for controlling image forming apparatus

Publication Date: 2014.07.29 BROTHER KOGYO KK

AI summary

In an image forming apparatus, developer remaining on a photosensitive member as transfer residual developer is caught temporarily by a catching portion. In a collecting process, the transfer residual developer caught by the catching portion is returned to the photosensitive member, the transfer residual developer then is transferred onto a conveyor member, and the transfer residual developer is collected by a collecting portion. In the collecting process, the presence or absence or an amount of the transfer residual developer transferred onto the conveyor member is measured.