Multi-Wavelength Toner Patch Sensor Calibration
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Solution Overview
Problem
Existing toner patch sensors in image forming devices face accuracy issues due to variations in reflectivity caused by toner particle size, accumulation of toner resin and extraparticulate particles, and mechanical positioning, leading to inconsistent color reproduction.
Innovation Solution
A method and system that utilize a light source emitting and detecting light at multiple wavelengths in the infrared spectrum to measure toner patch reflectivity, with a processor adjusting operating parameters based on the detected signals to ensure accurate toner density control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single infrared wavelength is used for toner reflectivity measurement, then the device complexity is reduced, but the measurement precision deteriorates due to variations in reflectivity caused by toner particle size, accumulation of toner resin, and mechanical positioning
Solution Approach 1:
The measurement is segmented into multiple wavelength components. Instead of using a single wavelength, the patent employs multiple discrete infrared wavelengths (e.g., 880nm, 940nm, and potentially others) to measure reflectivity. Each wavelength provides independent measurement data that collectively compensates for variations caused by toner particle size, resin accumulation, and mechanical positioning, thereby improving measurement precision without significantly increasing overall system complexity
Solution Approach 2:
The patent changes the measurement parameter from a single wavelength to multiple wavelengths. By measuring reflectivity at different infrared wavelengths and analyzing the spectral characteristics, the system can distinguish between actual toner density variations and artifacts caused by particle size, resin accumulation, or positioning errors. This parameter change enables more accurate toner density measurement while maintaining relatively simple sensor hardware
2Reliability
If toner patch sensors are used to monitor toner density, then color balance control is improved, but reliability deteriorates over time due to accumulation of toner resin and extraparticulate particles on the control surface
Solution Approach 1:
The patent implements a feedback mechanism where the multi-wavelength reflectivity measurements are continuously monitored and used to adjust operating parameters. The system compares measured reflectivity values against reference values and automatically compensates for drift caused by resin accumulation or particle size variations. This feedback loop maintains reliable color balance control over time by continuously correcting for environmental and aging effects
Solution Approach 2:
The system changes from single-wavelength to multi-wavelength measurement parameters, enabling it to detect and compensate for changes in toner properties over time. By analyzing reflectivity across multiple wavelengths, the system can distinguish between actual toner density changes and changes caused by resin accumulation or particle size variations, thereby maintaining measurement precision and reliability throughout the device's operational life
3Device complexity
If mechanical positioning and orientation of toner patch sensor components are used, then the device complexity is reduced, but measurement precision deteriorates due to variations in signal magnitudes from one printer to the next
Solution Approach 1:
The patent transitions from relying on precise mechanical positioning to using optical parameter variations (multiple wavelengths) for measurement. By measuring reflectivity at multiple wavelengths and analyzing the spectral signature, the system becomes insensitive to minor variations in sensor positioning or orientation between different printers. This parameter change eliminates the need for complex mechanical positioning mechanisms while maintaining high measurement precision across multiple devices
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 approach enhances the accuracy of toner density measurement and control, leading to consistent color reproduction by compensating for variations in reflectivity and mechanical factors, thereby improving the reliability of color printing.
Implementation Method 1
the toner patch reflecting light in a plurality of wavelengths in the infrared spectrum
Data Source
AI summary
The present disclosure relates to a method, system and apparatus for calibrating toner measurement in an image forming device. A toner patch is deposited onto a control surface, the toner patch reflecting light in a plurality of wavelengths in the infrared spectrum. A toner patch sensor emits light at the plurality of wavelengths in the infrared spectrum onto the toner patch. The amount of incident light reflected from the toner patch at the plurality of wavelengths from the emitted light is measured, and used to generate measured signals indicative of the reflectivity of the toner patch. An operating parameter of the image forming device is adjusted based upon the measured signals.