Dynamic Toner Supply Control for Image Fogging Prevention
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Solution Overview
Problem
Conventional image forming apparatuses face issues with toner agitation and charging during high printing ratios, leading to image fogging and toner scattering due to excessive toner supply, and struggle to maintain a consistent toner level in the developer container.
Innovation Solution
An image forming apparatus with a developing apparatus that includes a detector to measure toner consumption and a controller to adjust the toner supply based on a calculated supply threshold value, taking into account the operating state and environmental conditions, ensuring appropriate toner agitation and charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If toner is supplied in large amounts to maintain consistent toner level, then toner level consistency is improved, but image fogging and toner scattering occur due to excessive toner supply
Solution Approach 1:
The patent changes the parameter of toner supply amount from fixed to variable, adjusting it based on detected toner consumption. The controller dynamically modifies the supply threshold value according to operating conditions (printing ratio, environment, developing apparatus state), preventing excessive toner supply that causes fogging while maintaining consistent toner levels.
Solution Approach 2:
The patent implements a feedback mechanism where a detector measures actual toner consumption, and the controller uses this information to adjust the toner supply amount. The supply threshold value is corrected based on detected consumption patterns, creating a closed-loop control system that prevents both toner shortage and excessive supply.
2Stability of the object's composition
If toner supply is increased to account for high printing ratio consumption, then toner level maintenance is improved, but agitation and charging become insufficient leading to image failures
Solution Approach 1:
The patent makes the toner supply system dynamic by adjusting the supply threshold value based on real-time detection of toner consumption and operating conditions. Instead of fixed supply amounts, the system adapts supply parameters to current printing ratio, environment, and developing apparatus state, ensuring reliable agitation and charging.
Solution Approach 2:
The patent performs preliminary detection of toner consumption before initiating toner supply. The controller calculates the corrected supply threshold value in advance based on detected consumption patterns and operating conditions, ensuring that toner is supplied at the appropriate time and amount to maintain image quality.
3Device complexity
If fixed toner supply amount is used, then supply control is simplified, but toner consumption variation due to printing ratio and environment cannot be compensated
Solution Approach 1:
The patent enables the toner supply system to self-adjust by detecting actual toner consumption and automatically correcting the supply threshold value. The detector and controller work together to make the system self-regulating, compensating for variations in printing ratio and environmental conditions without manual intervention.
Solution Approach 2:
The patent changes the supply control parameter from a fixed value to a dynamically corrected value. The controller modifies the toner supply threshold based on detected consumption patterns, operating conditions, and environmental factors, maintaining toner level stability while adapting to varying demands.
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
The solution effectively reduces image failures, maintains a consistent toner level, and prevents toner fogging and scattering by optimizing toner supply during high printing ratios, while ensuring efficient toner usage and maintaining image quality.
Implementation Method 1
a detector to detect an amount of toner consumed
Implementation Method 2
a controller to adjust the toner supply based on a calculated supply threshold value, taking into account the operating state and environmental conditions
Implementation Method 3
a developing apparatus that employs electro-photography, for example, to form a latent image on an image bearing member
Implementation Method 4
a laser irradiation unit 53, which serves as an exposing apparatus, exposes the surface of the photosensitive drum 51, in consonance with image data, and forms an electrostatic latent image thereon
Implementation Method 5
a transferring field that is formed between the photosensitive drum 51 and a transferring roller 56 that serves as a transferring unit, the toner image is electrostatically transferred to a recording material P by a transferring roller 56
Implementation Method 6
a fixing apparatus 58 employs heat and pressure to permanently fix the toner image to the recording material P
Implementation Method 7
residual toner on the surface of the photosensitive drum 51 is removed by a cleaning apparatus 57, for which a blade shaped cleaning member is provided
Data Source
AI summary
An image forming apparatus is provided which includes a developing apparatus configured to form a developer image; a supply apparatus configured to supply developer to the developing apparatus; a detector configured to detect an amount of developer consumed during an image forming process; and a controller configured to perform an addition calculation for the amount of developer consumed, and for employing a value obtained by the addition calculation and a supply threshold value to determine whether developer should be supplied to the developing apparatus, wherein the controller sets the supply threshold value in accordance with an operating state of the developing apparatus.