Toner Patch Density Control for Image Forming Apparatus
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Solution Overview
Problem
Current image forming apparatuses face challenges in stabilizing image densities and reducing color misregistration without downtime, as existing techniques for reducing density variations and correcting misregistration are either time-consuming or lack accuracy due to limited toner patch formation outside the image area.
Innovation Solution
An image forming apparatus that forms a plurality of toner patches during a non-printing period for density detection and adjustment, and fewer toner patches during a printing period within the image area, allowing for continuous image output while maintaining stable density control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If toner patches are formed during a non-printing period to perform density detection and adjustment, then measurement precision and manufacturing precision are improved, but productivity deteriorates due to downtime
Solution Approach 1:
The system performs comprehensive density detection and adjustment during non-printing periods before actual image output begins. By conducting toner patch formation and density measurements in advance, the system ensures optimal image quality parameters are established before production starts, eliminating the need to interrupt ongoing printing operations for adjustments
Solution Approach 2:
The system maintains continuous image output capability by implementing density control during non-printing periods. The automatic adjustment mechanism operates continuously in the background during idle times, ensuring that density parameters are always optimized without interrupting the continuous flow of image production during printing periods
2Manufacturing precision
If the number of output sheets reaches a predetermined number and image-output processing is disabled to form toner patches, then manufacturing precision is improved, but productivity deteriorates due to interrupted output
Solution Approach 1:
The system proactively performs color registration adjustments during non-printing periods before density degradation occurs. By detecting and correcting registration issues in advance during idle times, the system prevents quality deterioration that would otherwise require interrupting ongoing printing operations
Solution Approach 2:
The system implements continuous monitoring of density and registration parameters during non-printing periods, using detector feedback to automatically adjust toner patch formation and development conditions. This closed-loop control ensures optimal color registration is maintained without manual intervention or printing interruptions
3Measurement precision
If toner patches are formed outside the image area to perform density correction, then measurement precision is improved, but device complexity increases due to limited patch formation space
Solution Approach 1:
The system divides the toner patch formation process into multiple discrete patches arranged in specific patterns outside the image area. By segmenting the measurement function into multiple separate patch locations, the system achieves comprehensive density coverage while working within the spatial constraints of the non-image area
Solution Approach 2:
The system utilizes the temporal dimension by forming and measuring toner patches during non-printing periods, effectively adding a time dimension to the spatial arrangement problem. This allows comprehensive density measurement without competing for space with the image area, as patches are formed and measured in the time domain rather than requiring additional spatial dimensions
Data Source
AI summary
An image forming apparatus includes a controller configured to control a toner-image forming device to form a toner patch; and a detector configured to detect the toner patch on the image carrier. During a non-printing period, the controller causes a toner-image forming device to form toner patches, causes the detector to detect densities of the toner patches, and adjusts an image-forming condition of the toner-image forming device based on detected densities. During a printing period, the controller causes the toner-image forming device to form an output image in an image area and form fewer toner patches in a non-image area, causes the detector to detect densities of the fewer toner patches, and adjusts the image-forming condition of the toner-image forming device based on detected densities. The fewer toner patches are selected from and fewer than the plurality of toner patches formed during the non-printing period.