Toner Image Formation Control for Scattering Reduction
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Solution Overview
Problem
In image forming apparatuses, the superposition of toner images from different units can lead to toner scattering when forming line images, particularly due to the use of white toner, which results in defective images.
Innovation Solution
The apparatus controls toner image formation by adjusting the toner usage per unit area, with the second image forming unit using less toner for line images compared to solid images, and employing different toner-image formation conditions for the upstream and downstream photoconductors to minimize scattering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the same amount of toner per unit area is used by both image forming units for line images, then the toner image formation is simple and consistent, but toner scattering occurs during transfer resulting in defective images
Solution Approach 1:
The patent applies local quality by differentiating toner usage based on image type. Specifically, when forming line images, the downstream image forming unit uses a smaller amount of toner per unit area compared to solid images. This localized adjustment in toner application prevents toner scattering during transfer while maintaining image quality, directly resolving the contradiction between reliability and device complexity.
2Reliability
If more toner is used per unit area by the second image forming unit for line images, then toner scattering is reduced, but toner waste increases and image density becomes excessive
Solution Approach 1:
The patent applies parameter changes by adjusting the toner amount parameter based on image type and image forming unit position. For line images, the downstream image forming unit uses a smaller amount of toner per unit area compared to solid images. This parameter optimization ensures sufficient toner adhesion to prevent scattering while avoiding excessive toner waste and maintaining proper image density.
3Manufacturing precision
If different toner amounts are used by upstream and downstream photoconductors, then toner scattering is minimized, but the control system becomes more complex
Solution Approach 1:
The patent implements local quality by assigning different toner usage characteristics to different image forming units based on their position in the transfer sequence. The downstream image forming unit specifically adjusts its toner amount for line images, creating a localized quality difference that ensures uniform toner distribution and prevents scattering during transfer, while the control complexity remains manageable through targeted adjustments.
Data Source
AI summary
An image forming apparatus includes image forming units, a transfer unit that transfers a superposed toner image including toner images formed by the image forming units onto a sheet, a fixing unit that fixes the superposed toner image onto the sheet, and a controller that performs control such that a toner image is formed while the amount of toner used per unit area by the second image forming unit when forming a line image is smaller than that when forming a solid image. The image forming units include a first image forming unit that forms a toner image that is transferred onto the transfer unit relatively earlier than the other toner images and a second image forming unit that forms a toner image that is transferred onto the transfer unit relatively later than the other toner images, the first and second image forming units using the same color toner.