Waste Toner Conveyance Control in Image Forming Apparatus
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Solution Overview
Problem
In electrophotographic image forming apparatuses, the waste toner storage portion can become excessively filled during high-quality or high-density image formation modes, leading to potential clogging issues due to the limited capacity and conveyance rate of the waste toner conveying system.
Innovation Solution
An image forming apparatus with a control unit that calculates the amount of waste toner stored during image forming periods and executes conveyance control by rotating the image bearing member during non-image forming times to reduce the toner storage in the waste toner storage portion, using a conveying unit driven by the image bearing member to transfer toner to a secondary storage unit when the threshold is reached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the waste toner storage portion volume is increased to prevent excessive storage during high-density image formation, then the waste toner storage capacity is improved, but the process cartridge size increases which contradicts the downsizing requirements
Solution Approach 1:
The conveying screw performs preliminary conveyance action during non-image forming periods (idle time) before the waste toner storage portion becomes completely full. The control unit monitors the amount of waste toner and activates the conveying screw to transfer toner to the collection container in advance, preventing excessive storage before it occurs.
Solution Approach 2:
The conveying screw operates periodically rather than continuously - it is activated at specific intervals during non-image forming periods when the control unit determines that waste toner accumulation has reached a level requiring conveyance. This periodic operation allows the system to maintain smaller storage volume while still preventing overflow.
2Productivity
If the conveying screw diameter is increased to improve waste toner conveyance rate during high-quality image formation, then the conveyance efficiency is improved, but the process cartridge volume increases which contradicts downsizing demands
Solution Approach 1:
The conveying screw performs conveyance action in advance during non-image forming periods, transferring waste toner to the collection container before the storage portion becomes full during high-density image formation. This preliminary action allows the use of a smaller diameter conveying screw while still maintaining adequate conveyance capability.
Solution Approach 2:
The system dynamically adjusts the operation timing of the conveying screw based on image formation mode and waste toner accumulation level. During standard mode, conveyance occurs at regular intervals, while during high-quality or high-density modes, the control unit monitors waste toner amount and activates conveyance more frequently or in advance, allowing a smaller screw to handle variable loads effectively.
3Device complexity
If the waste toner conveyance relies solely on photosensitive drum rotation during image formation, then the system simplicity is maintained, but the conveyance speed becomes insufficient during high-density image formation modes
Solution Approach 1:
The conveying screw operates periodically during non-image forming periods to transfer waste toner to the collection container. This periodic operation complements the continuous conveyance during image formation, ensuring that even high-density waste toner generation can be handled without requiring a more complex dual-drive system.
Solution Approach 2:
The system ensures continuous waste toner management by combining conveyance during image formation (driven by photosensitive drum rotation) with additional conveyance during non-image forming periods (driven by the conveying screw). This continuous action prevents waste toner accumulation without requiring a completely new conveyance mechanism.
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
Prevents excessive storage of waste toner in the storage portion, thereby preventing clogging and ensuring efficient conveyance to the collection container, even during high-demand image formation modes without increasing the storage volume or conveying member diameter.
Implementation Method 1
a conveying unit which is arranged to be driven by transmission of a rotation of the image bearing member to convey toner stored in the first storage unit to a distinct second storage unit
Data Source
AI summary
An image forming apparatus includes a cleaning unit removing toner remaining on an image bearing member after a toner image is transferred to an intermediate transfer member; a first storage unit which collects removed toner; a conveying unit which is driven by transmission of rotation of the image bearing member to convey toner in the first storage unit to a second storage unit; and a control unit which performs conveyance control, by driving the image bearing member to rotate during a non-image forming period, in which the conveying unit is caused to convey toner from the first storage unit to the second storage unit, wherein when an amount of toner in the first storage unit is equal to or larger than a threshold during an image forming period, the control unit executes the conveyance control during the non-image forming period to reduce the toner in the first storage unit.