Image Forming Apparatus Toner Distribution Control

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Solution Overview

Problem

Image forming apparatuses face challenges in maintaining optimal toner concentration across developer transport members, leading to issues such as toner fog and thin spots in printed images due to uneven toner distribution.

Innovation Solution

The apparatus employs a controller to adjust the voltage waveforms supplied to developer transport members, creating a potential difference that balances toner distribution between downstream and upstream rollers, ensuring consistent toner concentration and preventing toner fog while compensating for toner shortages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the toner concentration in the developer container is high, then the developer can be supplied sufficiently to the latent image carrier, but toner fog occurs and image quality deteriorates

Engineering Contradiction:
Improvetoner concentration in developerVSAvoidtoner fog
Core Design Contradiction:
Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by differentiating the treatment of toner concentration across different developer transport members. When the container toner concentration is high, the system selectively decreases toner concentration at the downstream transport member while maintaining or increasing it at upstream transport members. This localized differentiation prevents toner fog at the critical downstream region where it contacts the latent image carrier, while preserving sufficient toner supply from upstream regions.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent implements dynamics by making the toner concentration distribution adaptive and time-varying. The controller dynamically adjusts the voltage waveforms supplied to developer transport members based on real-time feedback from the toner concentration detector. When high toner concentration is detected, the system actively modulates the concentration distribution across transport members, creating a dynamic response that prevents toner fog while maintaining image quality.

Inventive Principle:
Principle #15Dynamics

2Object-affected harmful factors

If the toner concentration in the developer container is low, then toner fog is prevented, but thin spots occur in the printed image

Engineering Contradiction:
Improvetoner fogVSAvoidtoner concentration uniformity on latent image carrier
Core Design Contradiction:
Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The patent applies local quality by differentiating the treatment of toner concentration across different developer transport members. When the container toner concentration is low, the system selectively increases toner concentration at downstream transport members while decreasing it at upstream transport members. This localized differentiation ensures sufficient toner reaches the latent image carrier to prevent thin spots, while avoiding excessive accumulation that would cause toner fog.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent implements feedback by using a toner concentration detector to continuously monitor the developer container and adjusting the voltage waveforms of developer transport members accordingly. The controller receives feedback from the detector and dynamically modifies the toner distribution strategy - increasing downstream concentration when container levels are low to prevent thin spots, while decreasing it when levels are high to prevent toner fog, thus maintaining manufacturing precision.

Inventive Principle:
Principle #23Feedback

3Device complexity

If voltage waveforms with identical periods are supplied to all developer transport members, then the system operation is simple, but toner concentration cannot be balanced among multiple transport members

Engineering Contradiction:
Improvevoltage control systemVSAvoidtoner concentration distribution
Core Design Contradiction:
Device complexityVSQuantity of substance

Solution Approach 1:

The patent implements dynamics by making the voltage waveform phases variable while maintaining identical periods. The controller dynamically adjusts the phase relationships between voltage waveforms supplied to different developer transport members based on real-time toner concentration feedback. This dynamic phase modulation enables precise control of toner distribution among multiple transport members without increasing the fundamental period complexity, achieving balanced toner concentration through temporal differentiation.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent applies periodic action by using voltage waveforms with identical periods that are phase-shifted relative to each other. The periodic nature of these waveforms creates repeating potential difference patterns that rhythmically redistribute toner among transport members. This periodic phase-shifted action enables systematic toner concentration balancing across multiple transport members while maintaining relatively simple voltage control architecture.

Inventive Principle:
Principle #19Periodic action

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 solution effectively maintains optimal toner concentration, reducing toner fog and thin spots by dynamically controlling toner distribution, thereby enhancing image quality and reliability.

Implementation Method 1

a power supply that supplies voltages having plural waveforms having an identical period to the plural developer transport members... voltages having the waveforms that generate a potential difference therebetween, the potential difference causing the toner concentration of the developer distributed to a most downstream developer transport member to decrease and the toner concentration of the developer distributed to at least one of the developer transport members that is disposed upstream of the most downstream developer transport member to increase

Methodology Applied
Scientific EffectElectrostatic force: Electrostatics

Data Source

PatentUS8862005B2Image forming apparatus
Publication Date: 2014.10.14 FUJIFILM BUSINESS INNOVATION CORP
  • US8862005B2 patent drawing
  • US8862005B2 patent drawing
  • US8862005B2 patent drawing

AI summary

An image forming apparatus includes a latent image carrier, a container that contains a developer including a toner, developer transport members disposed so that peripheral surfaces thereof face the latent image carrier, a power supply that supplies voltages to the developer transport members, a detector that detects a toner concentration of the developer, and a controller. The controller performs control so that the power supply supplies to the developer transport members, when the toner concentration detected by the detector is higher than a predetermined upper limit, voltages having waveforms that generating a potential difference therebetween that causes the toner concentration of the developer distributed to a most downstream developer transport member to decrease and the toner concentration of the developer distributed to at least one of the developer transport members that is disposed upstream of the most downstream developer transport member to increase.