Toner Layer Forming Unit Captures Adhesive Waste
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Solution Overview
Problem
Image forming apparatuses face issues with foreign matters like adhesives and cutting waste from paper ends being transferred to transfer units, leading to wear and failure, particularly in secondary transfer units, due to inadequate prevention methods.
Innovation Solution
An image forming apparatus with a toner layer forming unit that creates a toner layer of predetermined width on the image carrying member, such as an intermediate transfer belt, to capture and transfer the adhesive or cutting waste with the paper, preventing it from adhering to the transfer unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate external additive is supplied to prevent adhesive attachment to the photoreceptor, then adhesive transfer is reduced, but the amount of protective particles is insufficient
Solution Approach 1:
A toner layer is formed on the image carrying member to serve as an intermediary protective barrier. This toner layer intercepts adhesive projecting from the paper end, preventing it from reaching and attaching to the photoreceptor or transfer unit members. The toner layer acts as a sacrificial mediator that absorbs the harmful adhesive instead of allowing it to damage critical components.
Solution Approach 2:
The toner layer is formed in advance on the image carrying member before the paper passes through the transfer unit. This preliminary formation of the protective toner layer ensures that when adhesive projects from the paper end during transfer, there is already a sufficient barrier in place to capture and contain the adhesive, preventing it from reaching the photoreceptor or transfer unit.
2Productivity
If adhesive projects from the end portion of label paper during secondary transfer, then adhesive is transferred to the intermediate transfer belt, but this causes abnormal wear and failure of transfer units
Solution Approach 1:
The invention converts the potentially harmful adhesive projection into a beneficial effect by directing it toward a sacrificial toner layer instead of critical components. The adhesive that would normally damage the transfer unit is now captured by the toner layer, which is designed to be replaceable. This transforms a harmful adhesive transfer into a controlled process where the adhesive is contained in a non-critical area.
Solution Approach 2:
The toner layer serves as a disposable protective element that can be replenished or replaced. Instead of trying to prevent adhesive projection entirely (which would require complex modifications to the transfer process), the invention uses a sacrificial toner layer that absorbs the adhesive damage. When the toner layer becomes contaminated, it can be replenished, avoiding the need to replace expensive transfer unit components.
3Ease of operation
If cutting waste is attached to the end portion of long paper, then it may be peeled off and attached to the intermediate transfer belt, but this leads to abnormal wear of cleaning devices
Solution Approach 1:
The toner layer on the image carrying member serves as an intermediary barrier that captures cutting waste and adhesive before they can reach the transfer unit or cleaning device. This protective layer absorbs the mechanical and adhesive stress from paper end contaminants, preventing them from damaging the cleaning device or intermediate transfer belt.
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
Effectively prevents foreign matters from adhering to transfer unit members, reducing wear and failure, and maintaining image quality by ensuring reliable transfer of toner images without adhesive contamination.
Implementation Method 1
the adhesive may project from the end portion of the paper, and is transferred to and is attached to the intermediate transfer belt
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An image forming apparatus of the present invention includes an image carrying member capable of carrying an image, a paper conveying unit, a toner layer forming unit, and a transfer unit. The paper conveying unit conveys a paper to the image carrying member. The toner layer forming unit forms a toner layer having a predetermined width at an outer side of the paper from a position corresponding to an end portion of the paper on a surface of the image carrying member. The transfer unit conveys the paper in press-contact with the image carrying member with the formed image and toner layer and transfers the image to the paper.