Image forming apparatus

An image forming apparatus includes a plurality of N image carriers including first through Nth image carriers, a transfer unit including an endless transfer belt, a plurality of M belt supporting members including a plurality of first through Nth nip opposing members contacting the inner surface of the endless transfer belt at positions corresponding to where the plurality of N image carriers contacts the outer surface of the endless transfer belt to form N transfer nips thereat, the first opposing member defining a first supported area of the endless transfer belt, a contact and separation mechanism including a retaining unit to move the first supported area of the endless transfer belt into and out of contact with the first image carrier, and a mark detector to detect a plurality of adjacent marks formed at a predetermined pitch in a circumferential direction of the endless transfer belt.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present invention claims priority pursuant to 35 U.S.C. §119 from Japanese Patent Application No. 2009-103879, filed on Apr. 22, 2009 in the Japan Patent Office, which is hereby incorporated by reference herein in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Exemplary embodiments of the present invention relate to a tandem-type image forming apparatus for transferring toner images formed on multiple image carriers onto a belt member or a recording medium to form a composite color image.

2. Discussion of the Related Art

Tandem-type image forming apparatuses generally have a transfer nip that is a contact area formed between each of multiple image carriers and a belt member held in contact with the multiple image carriers. Respective single-color toner images formed on the multiple image carriers are transferred sequentially onto either the belt member or a recording medium carried on the belt member at the respective transfer nips to form a multi-color or composite color toner image.

In this configuration, the belt member is driven at a constant speed by a belt drive motor. However, the speed of the belt member can vary due to, for example, eccentricity of extension rollers that extend to tension the belt member, eccentricity of drive gears, and/or uneven thickness in a circumferential direction of the belt member. If the speed of the belt member varies during a primary transfer operation for overlaying toner images on the belt member, the colors of the toner images may be displaced or shifted, resulting in significant deterioration in image quality or production of defective images.

Some image forming apparatuses employing a tandem-type image forming units include technologies to suppress occurrence of the above-described color shift caused by fluctuation in the velocity of the belt member. For example, the image forming apparatus may include a belt member with a scale formed thereon. The scale includes multiple marks formed at given pitches in the circumferential direction of the belt member. The image forming apparatus also includes a scale sensor to detect the multiple marks of the scale. A controller then detects the speed of the belt member based on time intervals between successive detections of the scale marks, and based on the detection results, controls the drive speed of a belt drive motor to reduce fluctuation in the velocity of the belt member.

Although generally successful, the related-art image forming apparatus having the above configuration cannot completely reduce or prevent color shift because fluctuation in the velocity of the belt member does not occur equally over the entire circumferential length of the belt member, as illustrated, for example, inFIG. 1.

FIG. 1illustrates a configuration of a transfer unit200incorporated in a related-art image forming apparatus.

The transfer unit200includes a transfer belt member201that is supported by a drive roller202disposed to an inner surface of the transfer belt member201, a driven roller203, a tension roller204, and four primary transfer rollers205a,205b,205c, and205d. With this configuration, the surface speed of the belt member at each of the transfer nips formed between photoconductors210a,210b,210c, and210dand the primary transfer rollers205a,205b,205c, and205d, respectively, depends on which area of the transfer belt member201enters the position where the transfer belt member201is wound around the drive roller202.

Specifically, the transfer belt member201may have at least an uneven thickness in the circumferential direction thereof. Further, the drive roller202and the tension roller204may be slightly eccentrically mounted on their shafts. In addition, the speed of the transfer belt member201at each transfer nip can also fluctuate due to the eccentricity of the drive roller202. Therefore, the fluctuation in the velocity of the transfer belt member201that is observed at each transfer nip is a combination or superimposition of a component of fluctuation in the belt velocity due to the thickness fluctuation of the transfer belt member201and a component of fluctuation in the belt velocity due to eccentricity of the drive roller202.

Accordingly, the surface speed of the transfer belt member201may vary at each transfer nip. However, the surface speed of the transfer belt member201may be different at the transfer nips and in a belt tensioned area between the tension roller204and the driven roller203, because the speed of the transfer belt member201varies in the belt tensioned area due to the fluctuation in belt thickness at the belt wound area of the drive roller202and the eccentricity of the drive roller202and due to the fluctuation in the belt thickness at the belt wound area of the tension roller204and the eccentricity of the tension roller204. In the belt tensioned area, the velocity fluctuation in which these velocity fluctuations are superimposed onto each other may occur on the surface of the transfer belt member201.

Further, it is typical to provide a contact and separation mechanism to move the transfer belt member201into and out of contact with the photoconductors for yellow, magenta, and cyan toner images. In the configuration with the contact and separation mechanism, regardless of the operations performed by the contact and separation mechanism, it is preferable that the scale sensor detects the multiple marks of the scale formed on the transfer belt member.

SUMMARY OF THE INVENTION

Exemplary aspects of the present invention have been made in view of the above-described circumstances.

Exemplary aspects of the present invention provide an image forming apparatus that can effectively avoid unnecessary driving of photoconductors and prevent color shifting caused by the fluctuation of velocity of a belt member by detecting marks of a scale formed on the belt member accurately regardless of movement of a contact and separation mechanism.

In one exemplary embodiment, an image forming apparatus includes a plurality of N image carriers, a transfer unit, a plurality of M belt supporting members, a contact and separation mechanism, and a mark detector. The plurality of N image carriers, including first through Nth image carriers, carries toner images formed thereon, satisfying a relation of N≧2. The transfer unit includes an endless transfer belt an outer surface of which contacts the plurality of N image carriers, to successively transfer the toner images formed on the plurality of N image carriers onto either the outer surface of the endless transfer belt or a surface of a recording medium carried on the endless belt. The plurality of M belt supporting members are disposed in contact with an inner surface of the endless transfer belt to support the endless transfer belt, satisfying a relation of M>N. The plurality of M belt supporting members include a plurality of first through Nth nip opposing members contacting the inner surface of the endless transfer belt at positions corresponding to where the plurality of N image carriers contact the outer surface of the endless transfer belt to form N transfer nips thereat. The first nip opposing member defines a first supported area of the endless transfer belt in a circumferential direction thereof where the first nip opposing member contacts and supports the endless transfer belt. The contact and separation mechanism includes a retaining unit that supports at least the first nip opposing member and moves the retaining unit to move the first supported area of the endless transfer belt into and out of contact with the first image carrier. The mark detector is provided in proximity to the endless transfer belt, fixedly mounted on the retaining unit, and moved by the contact and separation mechanism together with the retaining unit that supports at least the first nip opposing member. The mark detector detects a plurality of adjacent marks formed at a predetermined pitch on the endless transfer belt in the circumferential direction of the endless transfer belt.

The above-described image forming apparatus may further include a controller operatively connected to the mark detector and to a motor that drives the endless transfer belt. The controller may control the motor speed to control a drive speed of the endless transfer belt based on detection results obtained by the mark detector.

The first nip opposing member and the first nip opposing member together may form an extreme downstream nip of the N transfer nips in a direction of rotation of the endless transfer belt with the endless transfer belt interposed therebetween. The retaining unit may include a first sub-retainer that retains the first nip opposing member and a second sub-retainer that retains the plurality of N nip opposing members other than the first nip opposing member. The contact and separation mechanism may include a first contact and separation unit to contact and separate the first supported area of the endless transfer belt to and from the first image carrier and a second contact and separation unit to contact and separate a second supported area of the endless transfer belt different from the first supported area and defines by where the plurality of N image carriers other than the first image carrier contacts the endless transfer belt to and from the plurality of N image carriers other than the first image carrier. The mark detector may be fixedly mounted on the first sub-retainer.

A black toner image may be transferred from one of the plurality of N image carriers onto one of the outer surface of the endless transfer belt and the recording medium at the extreme downstream transfer nip.

An extreme upstream belt supporting member may be disposed adjacent to and upstream from the Nth nip opposing member in the direction of rotation of the endless transfer belt and fixedly mounted on the second sub-retainer. The Nth nip opposing member and the Nth image carrier together may form an extreme upstream transfer nip with the endless transfer belt interposed therebetween. An extreme downstream belt supporting member may be disposed adjacent to and downstream from the first nip opposing member in the direction of rotation of the endless transfer belt and fixedly mounted on the first sub-retainer. The endless transfer belt may be tensioned in a straight line by and between the extreme upstream belt supporting member and the extreme downstream belt supporting member in the direction of rotation of the endless transfer belt.

A second upstream belt supporting member may be disposed adjacent to and upstream from the first nip opposing member in the direction of rotation of the endless transfer belt, and the first nip upstream member may be fixedly mounted on the first sub-retainer.

The mark detector may be fixedly mounted on the first sub-retainer to detect the plurality of marks formed on the endless transfer belt while the plurality of marks pass through a mark detection range defined by the belt supporting members. The mark detection range may extend from an area supported by the second upstream belt supporting member to an area supported by the extreme downstream belt supporting member in the direction of rotation of the endless transfer belt.

The plurality of marks may be arranged on the inner surface of the endless transfer belt and the mark detector may be fixedly mounted on the first sub-retainer to detect the plurality of marks in the mark detection range on the inner surface of the endless transfer belt.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, exemplary embodiments of the present invention are described.

Descriptions are given, with reference to the accompanying drawings, of examples, exemplary embodiments, modification of exemplary embodiments, etc., of an image forming apparatus according to the present invention. Elements having the same functions and shapes are denoted by the same reference numerals throughout the specification and redundant descriptions are omitted. Elements that do not require descriptions may be omitted from the drawings as a matter of convenience. Reference numerals of elements extracted from the patent publications are in parentheses so as to be distinguished from those of exemplary embodiments of the present invention.

The present invention includes a technique applicable to any image forming apparatus. For example, the technique of the present invention is implemented in the most effective manner in an electrophotographic image forming apparatus.

FIG. 2illustrates a schematic configuration of an image forming apparatus1according to an exemplary embodiment of the present invention.

With reference toFIG. 2, basic configuration and operations of the image forming apparatus1are described.

The image forming apparatus1can be any of a copier, a printer, a facsimile machine, a plotter, and a multifunction printer including at least one of copying, printing, scanning, plotter, and facsimile functions. In this non-limiting example embodiment, the image forming apparatus1functions as a full-color copying machine employing a tandem-type image forming mechanism with an intermediate transfer belt for electrophotographically forming a toner image based on image data on a recording medium (e.g., a transfer sheet).

The toner image is formed with four single toner colors, which are yellow, magenta, cyan, and black. Reference symbols “Y”, “M”, “C”, and “K” represent yellow color, magenta color, cyan color, and black color, respectively.

Since units and components with respective suffixes generally have similar configurations to each other, except for the colors of toners, it is also referred to without specific suffixes. At the same time, components and units provided in devices are denoted by common reference numerals without suffixes “Y”, “M”, “C”, and “K” that are generally used to distinguish the colors.

InFIG. 2, the image forming apparatus1includes a printing section120, a sheet feeding section100, and a document feeding and reading unit150that includes a scanner160and an automatic document feeder or ADF170. The scanner160that serves as a document reading device is fixedly mounted on the lower part of the printing section120to support the ADF170.

The sheet feeding section100illustrated inFIG. 2includes a paper bank101, two sheet feeding cassettes102and103disposed inside the paper bank101, pairs of sheet separation rollers104and105, a sheet feeding path106, and multiple pairs of conveyance rollers107.

The sheet feeding cassettes102and103accommodate respective stack of paper sheets or recording sheets therein.

According to control signals transmitted from the printing section120, one of the sheet feed rollers102aand103ais rotated to feed a recording sheet S placed on top of the stack of recording sheets accommodated in a corresponding one of the sheet feeding cassettes102and103toward the sheet feeding path106. The recording sheet S fed from the sheet feeding cassettes102and103is separated from the stack of recording sheets by a corresponding one of the pairs of sheet separation rollers104and105and is conveyed into the sheet feeding path106. The recording sheet S is then conveyed via transfer nips formed between the rollers of the multiple pairs of conveyance rollers107in the sheet feeding path106to a first branched path30of the printing section120.

The printing section120further includes four process units2Y,2M,2C, and2K for forming yellow (Y), magenta (M), cyan (C), and black (K) toner images, the first branched path30, a pair of sheet conveyance rollers31, a manual sheet tray32, a pickup roller33, a second branched path34, a separation roller35, a pre-transfer conveyance path36, a pair of registration rollers37, a sheet conveyance belt unit39, a fixing unit43, a switchback unit46, a pair of discharging rollers47, a discharging tray48, a switching claw49, an optical writing unit50, and a transfer unit60. The process units2Y,2M,2C, and2K further include drum-shaped photoconductors3Y,3M,3C, and3K, respectively. The photoconductors3Y,3M,3C, and3K serve as a plurality of N image carriers, satisfying a relation of N≧2.

The pre-transfer conveyance path36that conveys the recording sheet S is divided into two branches, which are a first branched path30and a second branched path34, at an upstream side from a position immediately before a secondary transfer nip, which will be described later. The recording sheet S that is conveyed out of the sheet feeding path106of the sheet feeding section100enters the first branched path30, then passes through a sheet conveyance nip formed between the pair of sheet conveyance rollers31disposed in the first branched path30to the pre-transfer conveyance path36.

The manual sheet tray32is mounted on one side of a housing of the printing section120in a manner openable and closable to the housing. The manual sheet tray32is opened to manually feed the recording sheet S of a stack of recording sheets placed on the manual sheet tray32. The recording sheet S placed on top of the stack of recording sheets on the manual sheet tray32is picked up by the pickup roller33, separated one by one by the separation roller35, and conveyed to the second branched path34. Then, the recording sheet S is conveyed via a registration nip formed between the pair of registration rollers37to the pre-transfer conveyance path36.

The optical writing unit50of the image forming apparatus1ofFIG. 2includes a laser diode, a polygon mirror, and various lenses. The laser diode is driven based on image data read by the scanner160, which is described later, or image data transmitted by an external personal computer to optically scan the photoconductors3Y,3M,3C, and3K of the process units2Y,2M,2C, and2K, respectively.

More particularly, the photoconductors3Y,3M,3C, and3K of the process units2Y,2M,2C, and2K are driven by respective drive units, not illustrated, to rotate in a counterclockwise direction inFIG. 2. The optical writing unit50emits a laser light beam L (seeFIG. 3) to the photoconductors3Y,3M,3C, and3K during rotation to irradiate respective surfaces of the photoconductors3Y,3M,3C, and3K in an axial direction as the photoconductors3Y,3M,3C, and3K rotate in a sheet traveling direction. With this action, an electrostatic latent image based on the image data of yellow, magenta, cyan, and black single color images are formed on the respective surfaces of the photoconductors3Y,3M,3C, and3K.

FIG. 3is an enlarged view of a part of an internal configuration of the printing section120.

InFIG. 3, each of the process units2Y,2M,2C, and2K integrally includes a corresponding one of the photoconductors3Y,3M,3C, and3K, and various image forming components and units disposed therearound as one unit supported by a common supporting member. The process units2Y,2M,2C, and2K are removably installed to the image forming apparatus1and the units and components of the process units2Y,2M,2C, and2K generally have similar configurations to each other, except for the toner colors. For example, the process unit2Y that forms a yellow toner image includes the photoconductor3Y, a developing unit4Y to develop an electrostatic latent image for yellow toner color formed on the surface of the photoconductor3Y into a yellow toner image.

The image forming apparatus1according to an exemplary embodiment of the present invention is a tandem-type image forming apparatus in which four process units (e.g., the process units2Y,2M,2C, and2K) are arranged along a direction of endless rotation of an intermediate transfer belt61, which is described later.FIG. 4illustrates an enlarged view of the process unit2Y incorporated in the image forming apparatus1according to an exemplary embodiment of the present invention.

As noted above, the units and components with respective suffixes generally have similar configurations to each other, except for the colors of toners. Therefore, even though the following description is given of a configuration of the process unit2Y, the description is also applied to the other configurations of the process units2M,2C, and2K.

The process unit2Y ofFIG. 4includes the photoconductor3Y and other image forming components and units such as the developing unit4Y, a photoconductor cleaning unit18Y, an electric discharging lamp17Y, and a charging roller16Y arranged around the photoconductor3Y.

The photoconductor3Y is a drum-shaped image carrier that is formed by a base tube covered by a photoconductive layer formed of photoconductive organic photoconductive material. Alternative to the drum-shaped photoconductor, an endless belt-shaped image carrier can be employed as the photoconductor3Y.

The developing unit4Y of the process unit2Y illustrated inFIG. 4employs a two-component developer to develop the electrostatic latent image into a visible toner image. The two-component developer, which is hereinafter referred to as a developer, includes magnetic carrier particles and non-magnetic yellow toner particles. The development4Y further includes an agitation compartment5Y for agitating the developer accommodated therein and a development compartment9Y for developing the electrostatic latent image formed on the photoconductor3Y into the visible toner image. Alternative to the two-component developer, a single-component developer that consists essentially of non-magnetic toner particles can be applied.

The agitation compartment5Y is located below or at a lower position than the development compartment9Y and includes a first conveyance screw6Y, a second conveyance screw7Y, a partition plate14Y, a toner density sensor8Y. The first conveyance screw6Y and the second conveyance screw7Y are located side by side in a horizontal manner with the partition plate14Y interposed therebetween. The toner density sensor8Y is mounted on the bottom of a casing of the process unit2Y.

The development section9Y includes a developing roller10Y and a doctor blade13Y.

The doctor blade13Y is provided in proximity to the developing roller10Y so that the leading edge of the doctor blade13Y can nearly contact the developing roller10Y.

The developing roller10Y is disposed facing the photoconductor3Y, exposed to the photoconductor3Y via an opening of the casing of the process unit2Y. The developing roller10Y includes a development sleeve11Y and a magnet roller12Y.

The development sleeve11Y has a tubular shape formed by non-magnetic material, and the magnet roller12Y is disposed inside or covered by the development sleeve11Y. The magnet roller12Y does not rotate and includes multiple magnets arranged in a circumferential direction thereof. The multiple magnets exert magnetic forces at respective predetermined positions in a direction of rotation of the developing roller10Y, with respect to the developer held on a surface of the development sleeve11Y so that the developer conveyed from the agitation compartment5Y can be attracted to the surface of the development sleeve11Y to form a magnetic brush along lines of the magnetic force on the surface of the development sleeve11Y.

The magnetic brush formed on the surface of the development sleeve11Y is regulated to an appropriate thickness when the surface of the development sleeve11Y passes by a position facing the doctor blade13Y as the development sleeve11Y rotates. The regulated magnetic brush then directs to a development area that is formed at a position facing the photoconductor3Y to perform development. In the development area, a development bias that is applied to the development sleeve11Y and an electrostatic latent image formed on the photoconductor3Y have a difference in electric potential therebetween, and the difference in electric potential enables the yellow toner in the magnetic brush on the surface of the development sleeve11Y to move to the electrostatic latent image for developing into the toner image. As the development sleeve11Y further rotates, the yellow toner is conveyed back to the development compartment9Y to be released from the surface of the development sleeve11Y according to the action of repulsion between magnetic fields formed between magnetic poles of the magnet roller12Y. The yellow toner is then returned to the agitation compartment5Y. According to detection results of the toner density sensor8Y, an appropriate amount of yellow toner is supplied to the developer accommodated in the agitation compartment5Y.

The photoconductor cleaning unit18Y employs one of widely used configurations, for example, in which the cleaning blade20Y including a rubber elastomer such as polyurethane rubber is pressed against the surface of the photoconductor3Y. In order to enhance the cleaning ability or cleanability, the image forming apparatus1employs a fur brush19Y whose circumferential surface contacts the photoconductor3Y is rotatably disposed in a direction indicated by arrow shown inFIG. 4. The fur brush19Y is also used to apply powder lubricant scraped from a solid lubricant, not illustrated, to the surface of the photoconductor3Y.

The toner adhering to the fur brush19Y is moved to an electric field roller21Y to which a bias voltage is applied while rotating and contacting the fur brush19Y in a counter direction. The toner is then scraped from electric field roller21Y by a scraper22Y to fall onto a toner collection screw23Y.

The toner collection screw23Y conveys the collected toner toward the end of the photoconductor cleaning unit18Y in a direction perpendicular to the surface of the drawing sheet ofFIG. 4, to an external recycling conveyance unit, not illustrated. The external recycling conveyance unit conveys the collected toner to the developing unit4Y for recycling.

The electric discharging lamp17Y electrically discharges the surface of the photoconductor3Y by emitting light. The discharged surface of the photoconductor3Y is uniformly charged by the charging roller16Y, and then exposed by the optical writing unit50. The charging roller16Y rotates while receiving a charge bias supplied by a power source, not illustrated.

Alternative to the charging method using the charging roller16Y, a scorotron charger method for charging the surface of the photoconductor3Y without contacting can be employed.

By using the above-described processes in the configuration as shown inFIG. 3, the yellow, magenta, cyan, and black toner images are formed on the respective surfaces of the photoconductors3Y,3M,3C, and3K of the process units2Y,2M,2C, and2K.

The transfer unit60is disposed below the process units2Y,2M,2C, and2K. The transfer unit60includes the intermediate transfer belt61that serves as an endless transfer belt spanned around and extended by multiple belt supporting rollers. The intermediate transfer belt61is rotated endlessly by a drive roller68in a clockwise direction while contacting the photoconductors3Y,3M,3C, and3K. By so doing, respective primary transfer nips NY, NM, NC, and NK shown inFIG. 5that are contact areas between the photoconductors3Y,3M,3C, and3K and the intermediate transfer belt61.

In a vicinity of the primary transfer nips NY, NM, NC, and NK where yellow, magenta, cyan, and black toner images are formed, primary transfer rollers62Y,62M,62C, and62K are disposed contacting an inner surface of the intermediate transfer belt61and held to contact the photoconductors3Y,3M,3C, and3K with the intermediate transfer belt61interposed therebetween. That is, the primary transfer rollers62Y,62M,62C, and62K are pressed against the intermediate transfer belt61.

A power source, not illustrated, applies a primary bias voltage to each of the primary transfer rollers62Y,62M,62C, and62K that serve as nip opposing members. With this configuration, a primary transfer electric field that a single color toner image formed on each of the photoconductors3Y,3M,3C, and3K onto the intermediate transfer belt61at the primary transfer nips NY, NM, NC, and NK for forming yellow, magenta, cyan, and black toner images.

As the intermediate transfer belt61rotates endlessly in a clockwise direction inFIG. 3and passes through the primary transfer nips NY, NM, NC, and NK for the yellow, magenta, cyan, and black toner images, the respective single color toner images formed on the photoconductors3Y,3M,3C, and3K are sequentially transferred onto an outer surface of the intermediate transfer belt61for primary transfer so as to form a four-color or multi-color toner image thereon.

A secondary transfer roller75is located below the intermediate transfer belt61inFIG. 3. The secondary transfer roller75is disposed contacting the outer surface of the intermediate transfer belt61and facing the transfer roller opposing roller65with the intermediate transfer belt61interposed therebetween. According to this configuration, the secondary transfer roller75and the transfer roller opposing roller65form a secondary transfer nip therebetween.

Either the transfer roller opposing roller65disposed contacting the inner surface of the intermediate transfer belt61and or secondary transfer roller75disposed outside the loop of the intermediate transfer belt61is applied with a secondary transfer electric bias by a power source, not illustrated, and the other of which is electrically grounded. Accordingly, a secondary transfer electric field is generated in the secondary transfer nip.

On the right side of the secondary transfer nip inFIG. 3, the pair of registration rollers, which is not shown in this figure, is disposed so that the recording sheet S nipped between the rollers is conveyed to the secondary transfer nip in synchronization with movement of the four-color toner image formed on the intermediate transfer belt61. In the secondary transfer nip, the four-color toner image formed on the intermediate transfer belt61is transferred onto the recording sheet S by the action of the secondary transfer electric field and the nip pressure for secondary transfer. Thus, the four-color toner image is combined with white color of the recording sheet and a full-color image is formed.

After passing through the secondary transfer nip, the outer surface of the intermediate transfer belt61carries residual toner that has not been transferred onto the recording sheet at the secondary transfer nip. The residual toner is removed by a belt cleaning unit76that presses against the intermediate transfer belt61, thereby cleaning the outer surface of the intermediate transfer belt61.

As previously shown inFIG. 2, the recording sheet that serves as a recording medium after passing through the secondary transfer nip is separated from the intermediate transfer belt61then conveyed to the sheet conveyance belt unit39. The sheet conveyance belt unit39includes an endless sheet conveyance belt40, a drive roller41, and a driven roller42. The endless sheet conveyance belt40is rotated by rotation of the drive roller41in a counterclockwise direction inFIG. 2while being wound and tensioned around the drive roller41and the driven roller42. Then, while holding the recording sheet received from the secondary transfer nip on a tensioned upper surface of the endless sheet conveyance belt40, the sheet conveyance belt unit39conveys the recording sheet to a fixing unit43according to the rotation of the rotation thereof.

The fixing unit43includes a fixing belt44tensioned by a drive roller and a heat roller that includes a heat source, and rotates the fixing belt44in a clockwise direction as the drive roller rotates. A pressure roller45disposed below the fixing belt44is held in contact against a tensioned lower surface of the fixing belt44. The full-color image formed on the recording sheet conveyed to the fixing unit43is fixed to the recording sheet by application of heat and pressure. Then, the recording sheet having the full-color image thereon is conveyed from the fixing unit43toward the switching claw49.

The switching claw49swings by the action of a solenoid, not shown, to switch the recording sheet conveyance path between a sheet discharging path and a switchback path. If the switching claw49is set to direct to the sheet discharging path, the recording sheet conveyed from the fixing unit43passes through the sheet discharging path and the pair of discharging rollers47to the discharging tray48to be stacked thereon.

The switchback unit46is disposed below the fixing unit43and the sheet conveyance belt unit39. If the switching claw49is set to direct to the switchback path, the recording sheet conveyed from the fixing unit43passes through the switchback path where the recording sheet is reversed upside down to the switchback unit46. Then, the recording sheet enters the secondary transfer nip again so that the secondary transfer process and the fixing process are performed for a toner image formed on the back side thereof.

The scanner160is fixedly mounted on the printing section120to serve as an image reading device for reading original documents. The scanner160includes a fixed reading unit161and a movable reading unit162.

The fixed reading unit161includes a light source, reflection mirrors, image reading sensors such as charge-coupled devices (CCDs), and so forth. The fixed reading unit161is located directly below a first contact glass, not illustrated, which is fixedly mounted on a casing upper wall of the scanner160so as to contact the original documents directly. When an original document that is conveyed by the ADF170slidably passes on the first contact glass, light emitted by the light source is reflected on the surface of the original document sequentially via multiple reflection mirrors, and the reflected light is received by the image reading sensor. By so doing, the original document is optically scanned without moving optical units and components such as the light source and the reflection mirrors.

By contrast, the movable reading unit162is located directly below a second contact glass, not illustrated, which is fixedly mounted on the casing upper wall of the scanner160so as to directly contact the original documents, and enables optical components and units such as light source and reflection mirrors to move from side to side inFIG. 2. As the optical components and units of the movable reading unit162move from the left side to the right side ofFIG. 2, the laser light beam emitted from the light source is reflected on an original document, not illustrated, placed on the second contact glass, then travels via multiple reflection mirrors, and is received by the fixed reading unit161of the scanner160. Thus, the original document is scanned while the optical components and units are being moved.

Next, a description is given of the transfer unit60and the photoconductors3Y,3M,3C, and3K, in reference toFIG. 5illustrating an enlarged view of the transfer unit60and the photoconductors3Y,3M,3C, and3K.

InFIG. 5, the intermediate transfer belt61rotates endlessly in a clockwise direction while being supported by eleven (11) belt supporting rollers that serve as a plurality of M belt supporting members arranged on the inner surface of the intermediate transfer belt61. The number of the plurality of M belt supporting members is greater than the number of the plurality of N image carriers, satisfying a relation of M>N.

To reduce the size of a belt tensioned area of the intermediate transfer belt61, a belt pressing roller74presses against the intermediate transfer belt61in the tensioned area to bend and form a recessed portion toward the inside of the loop of the intermediate transfer belt61at the lower left part ofFIG. 5.

These eleven belt supporting rollers that support the intermediate transfer belt61on the inner surface thereof are four primary transfer rollers62Y,62M,62C, and62K, a nip array entrance roller63, a tension roller64, a transfer roller opposing roller65, a secondary transfer nip entrance roller67, a drive roller68, a nip array exit roller69, and a nip array pre-exit roller70.

The primary transfer nip for black toner image is the extreme downstream transfer nip of the four primary transfer nips in the primary transfer operation. Further, the primary transfer nip for yellow toner image is the extreme upstream transfer nip of the four primary transfer nips in the primary transfer operation. For the image forming apparatus1, the primary transfer roller62K supports the intermediate transfer belt61from the inner surface at the extreme downstream transfer nip. The primary transfer rollers62Y,62M,62C, and62K are referred to as nip opposing members. In the image forming apparatus1according to an exemplary embodiment of the present invention, the primary transfer roller62K may be also referred to as a first nip opposing member and the primary transfer roller62Y may be also referred to as an Nth nip opposing member.

The primary transfer roller62Y serving as the Nth nip opposing member is disposed adjacent to the nip array entrance roller63that serves as an extreme upstream belt supporting member. The nip array entrance roller63is disposed adjacent to and upstream from the primary transfer roller62Y in a direction of rotation of the intermediate transfer belt61. The nip array exit roller69serving as an extreme downstream belt supporting member is disposed adjacent to and downstream from the primary transfer roller62K serving as the first nip opposing member in a direction of rotation of the intermediate transfer belt61. Further, the nip array pre-exit roller70serving as a second upstream belt supporting member is disposed adjacent to and upstream from the primary transfer roller62K in a direction of rotation of the intermediate transfer belt61.

The nip array pre-exit roller70, the primary transfer roller62K, and the nip array exit roller69are arranged sequentially in this order and held by a first bracket72that serves as a retaining unit and a first sub-retainer.

The transfer unit60includes a first contact and separation unit77that is formed by a first eccentric cam73and a first cam motor, not illustrated, for driving the first eccentric cam73. The first contact and separation unit77serving as a contact and separation mechanism swingably moves the first bracket72by changing the position where the first eccentric cam73abuts against the first bracket72that swings about a swing shaft72aaccording to movement of the first eccentric cam73. This action of the first bracket72moves the primary transfer roller62K that is held by the first bracket72to a direction close to the photoconductor3K or a direction away from the photoconductor3K. By so doing, the intermediate transfer belt61can be moved into and out of contact with the photoconductor3K. With this action of the first contact and separation unit77, the shape of a first tensioned area of the intermediate transfer belt61in the circumferential thereof where the primary transfer roller62K contacts and supports the intermediate transfer belt61at the upper right part ofFIG. 5may vary. However, the tension roller64that is urged in a direction toward the inner surface of the intermediate transfer belt61while being slidably held by a bracket, not illustrated, can prevent a significant fluctuation of the tension force of the intermediate transfer belt61by moving the tension roller64flexibly according to the shape change of the first tensioned area of the intermediate transfer belt61.

Further, the nip array entrance roller63, the primary transfer rollers62Y,62M, and62C are arranged sequentially in this order and held by a second bracket272that serves as a retaining unit and a second sub-retainer.

The transfer unit60includes a second contact and separation unit277that is formed by a second eccentric cam273and a second cam motor, not illustrated, for driving the second eccentric cam273. The second contact and separation unit277serving as a contact and separation mechanism swingably moves the second bracket272by changing the position where the second eccentric cam273abuts against the second bracket272that swings about a swing shaft272aaccording to movement of the second eccentric cam273. This action of the second bracket272moves the primary transfer rollers62Y,62M, and62C that are held by the second bracket272to a direction close to the photoconductors3Y,3M, and3C, respectively, or to a direction away from the photoconductors3Y,3M, and3C, respectively, as shown inFIG. 6. By so doing, the intermediate transfer belt61can be moved into and out of contact with the photoconductors3Y,3M, and3C. With this action of the second contact and separation unit277, the shape of a second tensioned area of the intermediate transfer belt61in the circumferential thereof where the primary transfer rollers62Y,62M, and62C contact and support the intermediate transfer belt61at the upper left part ofFIG. 6may vary. However, the tension roller64can prevent a significant fluctuation of the tension force of the intermediate transfer belt61by moving the tension roller64flexibly according to the shape change of the second tensioned area of the intermediate transfer belt61.

When the image forming apparatus1according to an exemplary embodiment of the present invention performs image forming operations in a color printing mode, the photoconductors3Y,3M,3C, and3K contact the intermediate transfer belt61, as shown inFIG. 5, so that the transfer nips for yellow image, magenta image, cyan image, and black image can be formed. Then, as the process units2Y,2M,2C, and2K develop respective toner images, the toner images are sequentially transferred from the photoconductors3Y,3M,3C, and3K onto the intermediate transfer belt61to form an overlaid or composite color toner image.

By contrast, when the image forming apparatus1according to an exemplary embodiment of the present invention performs image forming operations in a monochrome printing mode, the photoconductors3Y,3M, and3C are separated from the intermediate transfer belt61so that only the photoconductor3K contacts the intermediate transfer belt61, as shown inFIG. 6. Then, as only the process unit3K develops a black toner image while the photoconductors3Y,3M, and3C are not in operation, the black toner image is transferred from the photoconductor3K onto the intermediate transfer belt61.

As noted above, the photoconductors3Y,3M, and3C are separated from the intermediate transfer belt61and do not perform the image forming operation in the monochrome mode, which can avoid a decrease in mechanical lives of the photoconductors3Y,3M, and3C caused by unnecessary operations. Further, the photoconductor3does not contact the intermediate transfer belt61unnecessarily in this configuration, thereby avoiding a decrease in time period of mechanical lives of the photoconductors3Y,3M, and3C and the intermediate transfer belt61.

Further, when the image forming apparatus1according to an exemplary embodiment of the present invention stops the image forming operations, the photoconductors3Y,3M,3C, and3K are completely separated from the intermediate transfer belt61, as shown inFIG. 7. By so doing, the photoconductors3Y,3M,3C, and3K and the intermediate transfer belt61do not contact to each other unnecessarily when the image forming apparatus1is not in operation, and therefore a decrease in time period of mechanical lives of the photoconductors3Y,3M,3C, and3K and the intermediate transfer belt61does not occur.

A scale, not illustrated, is arranged at one end in a widthwise direction of the intermediate transfer belt61. The scale has multiple marks formed at a predetermined pitch or intervals on the intermediate transfer belt61in a circumferential direction or a direction of rotation of the intermediate transfer belt61. The multiple marks of the scale are detected by a scale sensor71that includes a reflective photosensor arranged on the inner surface of the intermediate transfer belt61. The scale sensor71serves as a mark detector to output a detection signal of each mark of the multiple marks to a control unit180that serves as a controller.

The image forming apparatus1according to an exemplary embodiment of the present invention further includes the control unit180, as shown inFIG. 5. The control unit180includes a central processing unit (CPU), a random access memory (RAM), a read-only memory (ROM), and so forth and controls the entire units and components of the image forming apparatus1.

The control unit180calculates and obtains a speed of rotation of the intermediate transfer belt61based on a time interval of a mark detection signal that is transmitted from the scale sensor71. Then, based on the calculation results, the control unit180drives a belt drive motor181that is connected to the control unit180, according to a drive speed pattern that has an inverted phase with respect to a fluctuation of speed of the intermediate transfer belt61. By so doing, a feed back control can be preformed to suppress the velocity fluctuation of the intermediate transfer belt61. The illustration of the control unit180and the belt drive motor181are omitted inFIGS. 6 and 7.

Next, a description is given of detailed configuration and operations of the image forming apparatus1according to an exemplary embodiment of the present invention.

As previously shown inFIG. 5illustrating the image forming apparatus1according to an exemplary embodiment of the present invention, the scale sensor71that serves as a mark detector is fixedly mounted on the first bracket72that serves as a retaining unit and a first sub-retainer. InFIG. 5, the mark detection surface of the scale sensor71is disposed facing up at a tensioned area defined by and between the nip array pre-exit roller70and the primary transfer roller62K on the inner surface of the intermediate transfer belt61across a predetermined gap formed therebetween. The scale sensor71detects the multiple marks of the scale formed on the intermediate transfer belt61in a mark detection range defined by the nip array pre-exit roller70and the nip array exit roller69, extending from an area supported by the nip array pre-exit roller70to an area supported by the nip array exit roller69.

The scale sensor71is retained by the first bracket72, together with the primary transfer roller62K that supports the intermediate transfer belt61at the transfer nip NK for black toner image from the inner surface of the intermediate transfer belt61, and detects the multiple marks on the intermediate transfer belt61in the vicinity of the primary transfer nip NK. According to the configuration, the speed of the intermediate transfer belt61in the primary transfer nip NK can be detected accurately.

Since the nip array pre-exit roller70, the primary transfer roller62K, and the scale sensor71are retained by the first bracket72, the gap formed between the tensioned area on the inner surface of the intermediate transfer belt61and the mark detection surface of the scale sensor71can remain constant, regardless of the operation of the first bracket72. That is, regardless of the contact and separation operation performed by the first contact and separation unit77, color shift caused by fluctuation of the velocity of the intermediate transfer belt61can be prevented accurately.

As noted above, the scale sensor71is fixedly mounted on the first bracket72to detect the multiple marks of the scale formed on the inner surface of the intermediate transfer belt61. However, the scale sensor71can be fixedly mounted on the first bracket72to detect a scale formed on the outer surface of the intermediate transfer belt61by using a C-shaped steel. In this case, the scale on the outer surface of the intermediate transfer belt61is preferably arranged outside the image forming area in the widthwise direction thereof.

Further, the configuration described above uses the scale that is previously printed on the intermediate transfer belt61. However, as an alternative to the previously printed scale, the scale can include multiple patch toner images to be formed on the outer surface of the intermediate transfer belt61by a process unit of any toner color. For example, the patch toner images disclosed in JPAP 2004-177507 can be employed.

As described above, the image forming apparatus1according to an exemplary embodiment of the present invention includes the first contact and separation unit77in which the photoconductor3K contacts and separates from the intermediate transfer belt61by moving the first bracket72into and out of contact with the intermediate transfer belt61and the second contact and separation unit277in which the photoconductors3Y,3M, and3C contact and separate from the intermediate transfer belt61by moving the second bracket272into and out of contact with the intermediate transfer belt61.

As an alternative configuration, the scale sensor71can be fixedly mounted on the second bracket272. However, it is preferable that the scale sensor71is fixedly mounted on the first bracket72to achieve the following effect. The color that can effectively suppress the deformation of toner image due to fluctuation of the velocity of the intermediate transfer belt61can be determined depending on which primary transfer nip of the four primary transfer nips NY, NM, NC, and NK are arranged at predetermined intervals in a straight line comes closest to the first bracket72.

When the scale sensor71is fixedly mounted on the first bracket72, the speed of the intermediate transfer belt61can be detected most accurately at the primary transfer nip NK, thereby suppressing the distortion of the black toner image most effectively. In general the black color toner is highly frequently used. Therefore, by fixedly mounting the scale sensor71on the first bracket72, the distortion of the black toner image that is most frequently output can be suppressed most effectively.

Further, the distance between the scale sensor71and the mark detection range of the intermediate transfer belt61can maintain constant regardless of the contact and separation operation performed by the first contact and separation unit77. By so doing, the intermediate transfer belt61can be free of bend or damage caused by the scale sensor71abutting against the intermediate transfer belt61, for example.

In the image forming apparatus1according to an exemplary embodiment of the present invention, the scale sensor71is fixedly mounted on the first bracket72. However, different from this configuration, the speed of the intermediate transfer belt61can be detected accurately at the primary transfer nip NK either in the color mode or in the monochrome mode if the scale sensor71is provided in proximity to either the entrance or the exit of the primary transfer nip NK on the outer surface of the intermediate transfer belt61.

However, when the first bracket72is moved away from the photoconductor3K to move the intermediate transfer belt61out of contact with the photoconductor3K, the intermediate transfer belt61may be separated significantly from the scale sensor71. Therefore, when the intermediate transfer belt61is separated from the photoconductor3K, the speed of the intermediate transfer belt61cannot be detected.

In recent years, a reduction in a rising time from the idling state to the printing state has been required, and therefore it may be required to detect the speed of the intermediate transfer belt61even when the intermediate transfer belt61is separated from the photoconductor3K.

In the image forming apparatus1according to an exemplary embodiment of the present invention, the distance between the intermediate transfer belt61and the mark detection surface of the scale sensor71can be retained to be substantially equal, regardless of the movement of the first bracket72. Therefore, even during the movement of the first bracket72, the intermediate transfer belt61can contact or separate from the photoconductor3K, and the scale sensor71can detect the multiple marks of the scale formed on the intermediate transfer belt61.

The nip array entrance roller63that serves as the extreme upstream belt supporting member is disposed adjacent to and upstream from the primary transfer roller62Y that supports the intermediate transfer belt61on the inner surface thereof where the primary transfer nip NY that corresponds to the extreme upstream nip of the four (or N) primary transfer nips NY, NM, NC, and NK. Further, the nip array exit roller69that serves as the extreme downstream belt supporting member is disposed adjacent to and downstream from the primary transfer roller62K that serves as the extreme downstream belt supporting member in a direction of rotation of the intermediate transfer belt61.

The transfer unit60holds the intermediate transfer belt61tensioned in a straight line, extending from an area supported by the nip array entrance roller63to an area supported by the nip array exit roller69in the direction of rotation of the intermediate transfer belt61, as shown inFIG. 5. In this configuration, an angle of approach to the primary transfer nip or a belt nip approach angle at the entrance of each primary transfer nip is set to be equal. Further, an angle of exit from the primary transfer nip or a belt nip exit angle at the exit of each primary transfer nip is also set to be equal. As a result, the primary transfer condition at or in proximity to each primary transfer nip is provided to be equal to reduce or prevent errors in the transferability of each color.

Further, in the image forming apparatus1according to an exemplary embodiment of the present invention, the first bracket72retains the nip array pre-exit roller70that serves as the second upstream belt supporting member as well as the nip array exit roller69that serves as the extreme downstream belt supporting member. With this configuration, by moving the nip array pre-exit roller70, the primary transfer roller62K, and the nip array exit roller69together by integrally mounting on the first bracket72, the tensioned area from the entrance of the primary transfer nip NK to the exit of the primary transfer nip NK can remain in a straight line as shown inFIG. 5, regardless of the contact and separation operations performed by the first contact and separation unit77and the second contact and separation unit277. Therefore, regardless of the contact and separation operations performed by the first contact and separation unit77and the second contact and separation unit277, the belt nip approach angle at the entrance of the primary transfer nip NK and the belt nip exit angle at the exit of the primary transfer nip NK can remain constant. Accordingly, regardless of the contact and separation operations, a constant transfer condition can be maintained at, before, or after the primary transfer nip NK.

The description above has been given of the image forming apparatus1in which toner images formed on the respective photoconductors3Y,3M,3C, and3K are successively transferred onto the surface of the intermediate transfer belt61. However, the technique of the present invention can also be applied to an image forming apparatus that has a configuration in which toner images formed on respective photoconductors are sequentially transferred and overlaid onto a recording medium carried on the surface of an endless belt member.

Further, the description above has been given of the image forming apparatus1in which the scale sensor71is fixedly mounted on the first bracket72. However, the technique of the present invention can also be applied to an image forming apparatus having a configuration in which a patch detection sensor is fixedly mounted on a bracket (e.g., the first bracket72). The patch detection sensor can detect patch images formed on the surface of a belt member using a color shift correction control. With the color shift correction control, the angles of the optical components and unit can be adjusted and the times of optical writing can be changed so as to correct color shifting caused by deviation of a small optical path or paths in an optical system (e.g., the optical writing unit50) due to change in temperature. To grasp a color shift amount of each color, the patch detection sensor is used to detect the patch images formed on the surface of the belt member.

As described above, the image forming apparatus1according to an exemplary embodiment of the present invention includes the primary transfer roller62K to serve as a first nip opposing member of the multiple belt supporting members and provides the primary transfer roller62K to support the intermediate transfer belt61from the inner surface at the extreme downstream transfer nip. The image forming apparatus1further includes the first contact and separation unit77and the second contact separation unit277. The first contact and separation unit77swingably moves the first bracket72serving as the retaining unit and the first sub-retainer by moving the first tensioned area of the intermediate transfer belt61defined by the primary transfer roller62K into and out of contact with the photoconductor3K that is disposed facing the primary transfer roller62K with the intermediate transfer belt61interposed therebetween. The second contact and separation unit277swingably moves the second bracket272serving as the retaining unit and the second sub-retainer by moving the second tensioned area of the intermediate transfer belt61defined by the primary transfer rollers62Y,62M, and62C into and out of contact with the photoconductors3Y,3M, and3C that are disposed facing the primary transfer rollers62Y,62M. and62C with the intermediate transfer belt61interposed therebetween. Further, a black toner image is transferred from the photoconductor3K onto the outer surface of the intermediate transfer belt61at the extreme downstream transfer nip. With this configuration, the black toner image that is most frequently produced for image forming and printing can be effectively prevented from the shape change caused by the fluctuation of the velocity of the intermediate transfer belt61.

Further, in the image forming apparatus1according to an exemplary embodiment of the present invention, the nip array entrance roller63is fixedly mounted on the second bracket272so that the nip array entrance roller63is disposed adjacent to and upstream from the primary transfer roller62Y in a direction of rotation of the intermediate transfer belt61, where the primary transfer roller62Y is supports the intermediate transfer belt61on the inner surface thereof and the primary transfer roller62Y and the photoconductor3Y form the extreme upstream transfer nip with the intermediate transfer belt61interposed therebetween. In addition, the nip array exit roller69is fixedly mounted on the first bracket72so that the nip array exit roller69is disposed adjacent to and downstream from the primary transfer roller62K serving as the first nip opposing member in a direction of rotation of the intermediate transfer belt61. Further, the intermediate transfer belt61tensioned in a straight line by and between the nip array entrance roller63disposed adjacent to and upstream from the primary transfer roller62Y and the nip array exit roller69disposed adjacent to and downstream from the primary transfer roller62K in the direction of rotation of the intermediate transfer belt61. With this configuration, each condition of the transfer nips NY, NM, NC, and NK can be provided to be equal to reduce or prevent errors of the transferability of each color.

Further, in the image forming apparatus1according to an exemplary embodiment of the present invention, the nip array pre-exit roller70is adjacent to and upstream from the primary transfer roller62K in the direction of rotation of the intermediate transfer belt61and is fixedly mounted on the first bracket72. With this configuration, regardless of the contact and separation operation performed by the first contact and separation unit77and the second contact and separation unit277, the belt nip approach angle at the entrance of the primary transfer nip NK and the belt nip exit angle at the exit of the primary transfer nip NK can be set to be equal. Accordingly, regardless of the operations of the first contact and separation unit77and the second contact and separation unit277, a constant transfer condition can be maintained at, before, or after the primary transfer nip NK.

Further, in the image forming apparatus1according to an exemplary embodiment of the present invention, the scale sensor71is fixedly mounted on the first bracket72so as to detect the multiple marks of the scale formed on the intermediate transfer belt61while the multiple marks pass through a mark detection range that is defined by and extends from an area supported by the nip array pre-exit roller70to an area supported by and the nip array exit roller69in the direction of rotation of the intermediate transfer belt61. With this configuration, the velocity of surface of the intermediate transfer belt61at the primary transfer nip NK can be detected with accuracy.

Further, in the image forming apparatus1according to an exemplary embodiment of the present invention, the multiple marks are arranged on the inner surface of the intermediate transfer belt61, and the scale sensor71is fixedly mounted on the first bracket72to detect the multiple marks in the mark detection range on the inner surface of the intermediate transfer belt61. With this configuration, the positions of units and components around the intermediate transfer belt61of the transfer unit60can be more flexibly arranged, compared with the configuration in which the scale sensor71is disposed on the outer surface of the intermediate transfer belt61.