Patent Publication Number: US-8543014-B2

Title: Image forming apparatus and method

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application claims priority under 35 U.S.C. 119 to U.S. Provisional Application Ser. No. 61/321,008, to Kobuse, filed on Apr. 5, 2010, the entire disclosure of which is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     Embodiments described herewith relate to an image forming apparatus, a toner cartridge, and a method of processing data recorded in a storage medium. 
     BACKGROUND 
     An image forming apparatus using an electrophotography consumes toner. When printing continues, the toner in a toner cartridge is used up someday. Thereafter, a person removes the toner cartridge from a main body of the image forming apparatus. The person sets a fresh toner cartridge filled with toner in the main body. 
     The toner cartridge fixes an IC (integrated circuit) chip to a wall of a container. The IC chip stores data for detecting that the toner cartridge is genuine goods. 
     Up to now, the data stored in the IC chip mounted on the toner cartridge is not erased. The IC chip remains fixed on the container. The data is still recorded in the IC chip even at a time when, due to the toner use up, the image forming apparatus is necessary to replace the toner cartridge with a fresh one. 
     However, that the data remains in the IC chip suffers from such a problem that a manufacturer other than a genuine manufacturer can easily copy the data. 
     A third party writes copy data on another storage medium. The third party attaches the storage medium onto a toner cartridge different from a genuine toner cartridge. 
     There is a drawback that the third party can easily copy the toner cartridge usable by an apparatus manufactured by the genuine manufacturer. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a configuration diagram of an image forming apparatus according to a first embodiment; 
         FIG. 2  is a back perspective view of a toner cartridge according to the first embodiment; 
         FIG. 3  is a flowchart for describing a method of processing data recorded in a storage medium according to the first embodiment; 
         FIG. 4  is a diagram illustrating a data configuration example in the storage medium used in the image forming apparatus according to the first embodiment; 
         FIG. 5  is a diagram illustrating a data configuration example in the storage medium at the time of detecting toner empty; 
         FIG. 6  is a diagram illustrating a data configuration example in a fresh storage medium; and 
         FIG. 7  is a flowchart for describing a method of processing data recorded in a storage medium according to a second embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Certain embodiments provide an image forming apparatus, including: a photoconductive drum on which an electrostatic latent image is formed through an electrophotography; a developing container configured to have a first chamber that contains a developer made of toner and a toner additive therein, and a receive port that communicates with the first chamber; a developing roller configured to develop the electrostatic latent image on the photoconductive drum with toner in the developing container; a toner cartridge configured to have a second chamber that contains a supply of toner to the developing container therein, and a discharge port that communicates with the second chamber and transport the supply of toner to the receive port; a storage medium configured to be fixed to the toner cartridge, and be rewritable and store specific data therein; a sensor configured to detect a toner concentration in the toner cartridge; and a controller configured to rewrite specific data stored in the storage medium by random data upon detecting the toner empty by the sensor. 
     Hereinafter, a description will be given in detail of an image forming apparatus, a toner cartridge, and a method of processing the data recorded in the storage medium with reference to the accompanying drawings. In the respective drawings, the same parts are indicated by identical symbols, and a repetitive description will be omitted. 
     First Embodiment 
     An image forming apparatus according to a first embodiment is directed to an MFP (multifunction peripheral) using an electrophotography. 
     A toner cartridge according to the first embodiment is directed to a toner cartridge with an IC chip. 
     A method of processing data according to the first embodiment is directed to a method of erasing specific data recorded in the IC chip of a genuine toner cartridge. 
       FIG. 1  is a configuration diagram of the MFP. The MFP  10  includes a main body  11 , a scanner part  12 , an image processing part  13 , a print process part  14 , a fixing unit  15 , a sheet feed unit  16 , a transport mechanism  17 , a controller  18 , and an operation panel  19 . 
     The scanner part  12  optically scans an original document surface. The scanner part  12  outputs image data as a read image signal. The image processing part  13  corrects the image data. 
     The print process part  14  forms an image on a sheet, and then outputs the sheet. The fixing unit  15  fixes an unfixed image on the sheet with the help of a heat roller  20  and a press roller  21 . 
     The sheet feeder  16  has two cassettes  22 . The sheet feeder  16  feeds the sheets to the print process part  14  with the help of pickup rollers  23 . 
     The transport mechanism  17  includes plural pairs of transport rollers  24 , a pair of registration rollers  25 , a transfer roller (an after-mentioned transfer unit  40 ), the heat roller  20 , the press roller  21 , and a pair of sheet exit rollers  26 . 
     The transport rollers  24  at an upstream side feed one sheet to a sheet path  27  (transport path). The transport mechanism  17  transports the sheet from the upstream side of the fixing unit  15  to a downstream side of the fixing unit  15  through the sheet path  27 . 
     The registration rollers  25  correct skew. As the transport mechanism  17 , the transport rollers  24  at the downstream side transports the sheet output by the fixing unit  15 . The sheet exit rollers  26  discharge the sheet to a tray  28 . 
     The controller  18  controls the operation of the entire MFP  10 . The controller  18  generates a print job. The controller  18  allows the transport mechanism  17  to transport the sheet. The controller  18  allows the print process part  14  to form an image on the sheet. 
     The controller  18  includes a CPU (central processing unit)  29 , a ROM (read only memory)  30 , and a RAM (random access memory)  31 . The ROM  30  stores a program for allowing the CPU  29  to execute the data processing method of this embodiment therein. 
     The operation panel  19  has a display  32  and a user interface part  33 . 
     The print process part  14  will be further described. 
     The print process part  14  includes an image formation part  34  and a laser exposure device  35 . The image formation part  34  forms a toner image on an image carrier through the electrophotography. The laser exposure device  35  modulates a laser diode with the image data. 
     The image formation part  34  includes a photoconductive drum  36 , a charging unit  37 , a developing unit  38 , a toner cartridge  39 , a transfer unit  40 , and a static eliminator  41 . 
     The photoconductive drum  36  is an image carrier that retains a latent image. The charging unit  37  charges the photoconductive drum  36 . The laser exposure device  35  reduces a charge potential of a portion of a surface of the photoconductive drum  36 , which is irradiated with a laser beam. 
     The developing unit  38  develops the latent image formed on the photoconductive drum  36 . The toner cartridge  39  is a toner supply device for the developing unit  38 . The transfer unit  40  transfers the toner image on the photoconductive drum  36  onto the sheet. The static eliminator  41  eliminates static electricity on the surface of the photoconductive drum  36 . 
     The developing unit  38  has a developer container  42  that is filled with a two-component developer. The developer is made of toner and carrier. The carriers have magnetic properties as toner additives. The developing unit  38  includes a developing roller  43 , and augers  44 ,  45  within the developer container  42 . 
     The developer container  42  includes a chamber (first chamber)  46 , a chamber  47 , and a wall  48 . The wall  48  allows the chambers  46  and  47  to partially communicate with each other. 
     The chamber  46  has a receive port  67 . The receive port  67  is coupled directly to the toner cartridge  39 . Alternatively, the receive port  67  is coupled to the toner cartridge  39  through a toner transport path. 
     The chamber  47  has an opening that faces the photoconductive drum  36 . The developing roller  43  is a magnet roller that carries the developer on an outer peripheral surface thereof. 
     The augers  44  and  45  stir and circulate the developer. The augers  44  and  45  feed the developer to the developing roller  43 . 
       FIG. 2  is a back perspective view of the toner cartridge  39 . A back surface  100  is at a depth side of the MFP  10 . A front surface  101  is at a front of the MFP  10 . Reference numerals described above indicate identical elements. 
     The toner cartridge  39  has a cartridge container  49 . The cartridge container  49  has a chamber  68  (second chamber) that contains a supply of toner to the developing unit  38  therein. The toner cartridge  39  has a toner exit port  50 . 
     The toner cartridge  39  has an auger  51  within the cartridge container  49 . The toner cartridge  39  receives a drive force for rotating the auger  51  from a coupler  52  in a state where the toner cartridge  39  is set in the main body  11 . 
     The toner cartridge  39  fixes an IC chip (storage medium)  56  to a side surface  102  of the cartridge container  49 . The IC chip  56  is equipped with a nonvolatile memory. The IC chip  56  stores the specific data therein. The specific data includes manufacturing records. The IC chip  56  is attached to the cartridge container  49  at the time of manufacturing the toner cartridge  39 . 
     The toner cartridge  39  has a circuit board  57 . The circuit board  57  is electrically connected to the IC chip  56 . The circuit board  57  has a plurality of terminals. A part of the terminals are covered with paint in advance. Upon setting the toner cartridge  39  in the main body  11 , the paint is scraped by contact. 
     The circuit board  57  has, as one example, an output terminal that outputs a sensor value from a sensor  60 , a terminal that outputs the specific data of the IC chip  56 , and an input terminal that causes random data recorded in the IC chip  56  instead of the specific data. 
     The circuit board  57  is electrically connected to a contact point of the main body  11  side in a state where the toner cartridge  39  is set in the main body  11 . The circuit board  57  receives a power supply from the main body  11  side. The data of the IC chip  56  is readable and writable by the controller  18 . 
     The toner cartridge  39  has the sensor  60  within the cartridge container  49 . The sensor  60  detects the concentration of toner. The toner concentration means a ratio of toner weight to carrier weight. The sensor  60  is formed of a general purpose IC using a piezoelectric element. 
     The sensor  60  causes the piezoelectric element and toner attached to the piezoelectric element resonate with each other. A resonance frequency of the piezoelectric element to which no toner is attached is higher than a resonance frequency of the piezoelectric element to which toner is attached. A difference between the frequencies is proportional to the amount of toner. The sensor  60  detects the toner concentration according to the amount of toner. 
     The sensor  60  is also electrically connected to the controller  18  by the circuit board  57  in a state where the toner cartridge  39  is set in the main body  11 . The controller  18  always monitors whether toner within the toner cartridge  39  is empty, or not, according to an output of the sensor  60 . 
     The developing unit  38  also has a toner sensor  55  for detecting the toner concentration in the developer container  42 . The controller  18  detects that toner within the developing unit  38  is decreased, from the toner sensor  55 . 
     The controller  18  rotationally drives the auger  51  within the toner cartridge  39  in one direction. The cartridge container  49  has a supply path inside. The auger  51  transports toner to the toner exit port  50 . The toner cartridge  39  transports toner to the developing unit  38 . 
     A method of eliminating the specific data by the MFP  10  configured as described above will be described with reference to  FIGS. 3 and 4 . 
       FIG. 3  is a flowchart for describing a method of processing the data recorded in the IC chip  56  of the toner cartridge  39 .  FIG. 4  is a diagram illustrating a data configuration example within the IC chip  56 . 
     When the IC chip  56  is manufactured prior to Act A 1  in  FIG. 3 , a manufacturing device writes information data specific to the toner cartridge  39  in a storage region  61 . 
     The information data includes, for example, a specific bit  62 , an old and new determination bit  63 , and a unique bit  64 . 
     The specific bit  62  represents information specific to the toner cartridge  39 . The specific bit  62  represents a manufacturing number, manufacture date, a production site, a manufacturer, the amount of toner, a toner color, and a version. 
     The old and new determination bit  63  represents information for determining whether the toner cartridge  39  is old and new. 
     If the toner cartridge  39  has never loaded in the MFP  10  yet, the old and new determination bit  63  of the toner cartridge  39  represents “1” (new). 
     The unique bit  64  represents information for determining whether the toner cartridge  39  is genuine, or not. The unique bit  64  stores, for example, an identification number of a service man allocated to each area therein. 
     In Act A 1  of  FIG. 3 , the MFP  10  loads the toner cartridge  39  filled with toner in the main body  11 . 
     In Act A 1 , the controller  18  reads the IC chip  56 . The controller  18  recognizes that the toner cartridge  39  is new, according to the old and new determination bit  63  indicative of “1”. 
     After recognition, the controller  18  rewrites the old and new determination bit  63  to “0” (old). 
     In Act A 1 , the controller  18  ensures all or a part of a region of the unique bit  64  for a counter for the number of prints. The controller  18  may write use history information such as the number of toner supply or a rotating speed of the auger  51  in the region. 
     In Act A 2 , the MFP  10  starts the use of the toner cartridge  39 . The MFP  10  inserts a plurality of original documents into an automatic document feeder  65 . 
     The automatic document feeder  65  repetitively feeds the original documents. The scanner part  12  repetitively generates image data for each page. The RAM  31  accumulates the image data for each page therein. The transport mechanism  17  transports the sheets one after another. The print process part  14  prints and outputs the sheets. 
     The transport mechanism  17  transports the sheets at time intervals one after another. The controller  18  increments a print counter of the IC chip  56  every time print is conducted. 
     During operation of the MFP  10 , the controller  18  monitors the toner concentration of the toner cartridge  39  through the sensor  60 . 
     In Act A 3 , if the toner concentration from the sensor  60  is smaller than a threshold value retained in advance, the controller  18  detects the occurrence of the toner empty. 
     In Act A 4 , the controller  18  eliminates the data in the IC chip  56 . 
       FIG. 5  is a diagram illustrating a data configuration example within the IC chip  56  at the time of detecting toner empty. 
     Upon reading empty from the sensor  60 , the controller  18  rewrites the data in the IC chip  56  to random data. 
     The random data represents a bit string of any bit pattern except for a bit pattern in which all of bit values are “0”, and a bit pattern in which all of bit values are “1”. 
     Write of the random data prevents a person different from a manufacturer of the genuine toner cartridge  39  from specifying the data in the IC chip  56 . 
     In Act A 5 , the controller  18  displays the toner empty on the operation panel  19 . The display of the operation panel  19  prompts an operator to exchange the toner cartridge  39  with a fresh one. The operator exchanges the toner cartridge  39  with a fresh one. 
     In Act A 6 , the controller  18  detects the exchange of the toner cartridge  39 . In Act A 7 , the controller  18  reads the data in the IC chip  56 . 
     In Act A 8 , the controller  18  determines whether the set toner cartridge is old or new, according to the value of the old and new determination bit  63  of the read data. 
     In Act A 8 , if the old and new determination bit  63  represents “0”, the controller  18  determines that the toner cartridge is old. 
     The controller  18  pass through a route of “old cartridge”, and in Act A 9 , the controller  18  displays that the toner cartridge should be discarded, on the operation panel  19 . 
     In Act A 8 , if the old and new determination bit  63  represents “1”, the controller  18  determines that the toner cartridge  39  is new. 
     The controller  18  passes through a route of “new cartridge”, and in Act A 10 , the controller  18  reads the data in the IC chip  56 . 
     In Act A 11 , the controller  18  determines whether the toner cartridge  39  is genuine and new, or not, according to the read data. 
       FIG. 6  is a diagram illustrating a data configuration example within the IC chip  56  of the new toner cartridge. The symbols described above represent identical elements. 
     In Act A 11 , the controller  18  determines that information of which the genuine manufacturer has knowledge is recorded in the unique bit  64 , and that the old and new determination bit  63  represents “1”. 
     Based on the determination result in Act A 11 , the controller  18  determines that the toner cartridge  39  is new and genuine. The controller  18  passes through a route of yes, and allows the operation panel  19  to cancel the empty display in Act A 12 . 
     In Act A 12 , the controller  18  allows the operation panel  19  to display a printable state. 
     After Act A 11  or A 12 , the controller  18  rewrites the old and new determination bit  63  to “0” (old). 
     In Act A 11 , if the controller  18  determines that the toner cartridge  39  is new but not genuine, the controller  18  passes through a route of no, and allows the operation panel  19  to continue the empty display in Act A 13 . 
     The operation panel  19  blinks, for example, a red lamp indicative of empty. 
     Thereafter, the controller  18  returns to processing in Act A 10 , and again reads the data in the IC chip  56 . 
     If control is conducted in a loop of Acts A 10 , A 11 , and A 13 , the controller  18  allows the operation panel  19  to continuously display that normal print operation is enabled. 
     The MFP  10  eliminates the data within the IC chip  56  as soon as the toner empty occurs. When toner is used up, and the user is going to exchange the toner cartridge  39  with a fresh one, the data has already been eliminated. 
     When the user exchanges the toner cartridge  39 , even if the user prepares a dedicated reader machine, the dedicated reader machine cannot read the data. 
     When toner becomes empty, the data within the IC chip is rewritten to the random data before the toner cartridge  39  is removed from the main body  11 . Ungenuine products or recycled products cannot be manufactured manufacturers other than the genuine manufacturer. 
     All the bit values of the bit pattern are all “0” or all “1” is assumed. A person who is going to replicate data senses that data is rewritten by a dedicated reader machine. Writing of the random data prevents even data rewriting from being sensed. 
     Ungenuine manufacturers cannot read the data with the help of the dedicated reader machine, and replicate the read data in another IC chip. A third party cannot attach the IC chip in which genuine data has been recorded to a toner cartridge made by the third party. The third party is difficult to replicate and manufactures the genuine toner cartridge. 
     In general, as products of the toner cartridges, there are genuine products and the ungenuine products. As the products of the toner cartridges, there are new products and recycled products. 
     A quality of the genuine toner cartridge  39  made by the manufacturer of the MFP  10  is higher than that of the toner cartridge manufactured by the third party. The genuine toner cartridge  39  brings out the performance of the MFP  10  at a maximum. 
     The controller  18  rewrites date to the random data before the operation panel  19  displays the data. The data in the IC chip  56  is not displayed. Specific information data is not leaked from the manufacture to the external. 
     If the information data is eliminated after the information data has been displayed on the operation panel, the information data is leaked from the manufacturer to the external. No specific data is leaked in the MFP  10 . The information data acquired by a person with a bad intension is not copied in an IC chip. 
     The ungenuine manufacturer cannot replicate the ungenuine toner cartridge or the recycled toner cartridge. 
     Second Embodiment 
     The example of the above first embodiment is the best mode. The person with a malicious intention attempts to detach the toner cartridge  39  from the main body  11 , and read the data within the IC chip  56  before toner empty occurs. 
     An image forming apparatus according to a second embodiment eliminates the data within the IC chip  56  before the toner empty occurs. 
     In the image forming apparatus according to the second embodiment, the ROM  30  stores a program of processing executed by the CPU  29  therein, which is different from a program of the processing in the first embodiment. 
     The image forming apparatus according to this embodiment is the MFP  10 . The MFP  10  is substantially identical with that in the first embodiment. 
     A cartridge according to this embodiment is the toner cartridge  39 . 
     A method of processing the data according to this embodiment is a method of eliminating specific data recorded in the IC chip  56 . 
       FIG. 7  is a flowchart for describing a method of processing the data recorded in the IC chip  56  of the toner cartridge  39  according to the second embodiment. 
     In Act B 1 , the MFP  10  is equipped with the toner cartridge  39  filled with toner. The old and new determination bit  63  of the IC chip  56  indicates new. 
     In Act B 2 , the controller  18  reads the IC chip  56 . The controller  18  recognizes that the toner cartridge  39  is new. The controller  18  rewrites the data to the random data. The data in the IC chip  56  is eliminated. 
     In Act B 3 , the controller  18  generates a counter for the number of prints in a region of the unique bit  64 . 
     In Act B 4 , the MFP  10  starts the use of the toner cartridge  39 . The MFP  10  repeats a print output. The controller  18  monitors the toner concentration of the toner cartridge  39 . 
     In Act B 5 , the controller  18  detects the occurrence of toner empty. 
     Thereafter, the controller  18  executes substantially the same processing as processing denoted by I in  FIG. 3 . 
     Subsequently, the toner cartridge  39  is new and genuine. The controller  18  allows the operation panel  19  to cancel empty display. The controller  18  allows the operation panel  19  to display a printable state. 
     The controller  18  eliminates the data immediately after the toner cartridge  39  has been loaded into the main body  11  of the MFP  10 . Even if the user detaches the toner cartridge  39  from the main body  11  before toner is empty, the user can no longer read the data. 
     The ungenuine manufacturer cannot replicate the ungenuine toner cartridge or the recycled toner cartridge. 
     Modified Example 
     The sensor  60  may be formed of a sensor that measures a magnetic permeability. The sensor  60  includes an oscillator circuit that generates a magnetic flux, and a coil circuit that detects a magnetic flux density that is changed according to the amount of magnetic carrier. The sensor  60  detects the toner concentration with a change in the magnetic permeability. 
     The sensor  60  may be formed of a sensor that detects the transmittance of light. The sensor  60  includes a light emitting element, a window in a developer, and a photo transistor that receives a transmitted light among an illuminating light. The sensor  60  detects the toner concentration with a change in the amount of received light. 
     The storage medium may be formed of an RFID (radio frequency identification) tag instead of the IC chip  56 . The MFP  10  has a noncontact data read and write device within the main body  11 . 
     The read and write device transmits and receives data with respect to the controller  18 . After the toner cartridge  39  is set in the MFP  10 , the read and write device reads information from the RFID tag, and eliminates data of the RFID. 
     Others 
     The image forming apparatus may be a printer or a copying machine. 
     The image forming apparatus may be an MFP, a printer, or a copying machine of colors. The image forming apparatus includes respective developing units of yellow (Y), magenta (M), cyan (C), and black (K), and toner cartridges for colors of the respective developing units. 
     A configuration and a structure of the toner cartridge  39  in  FIG. 2  is one example, and the configuration and the structure can be changed. The advantages of the image forming apparatus according to this embodiment are not impaired by products that merely change the configuration and the structure. 
     The data structure of the IC chip  56  is not limited to the example of  FIG. 4 . In the image forming apparatus according to this embodiment, the expressions and the bit regions of the specific bit  62 , the old and new determination bit  63 , and the unique bit  64  can be changed. 
     The image forming apparatus can use any data structure. 
     For example, the image forming apparatus may discriminate the old and new determination bit by a fuse element. The fuse element is melted by a limit current. The controller  18  may cut the fuse element by the circuit board  57  when rewrite is conducted from new to old. 
     The controller  18  may include a code generator that generates the random data. The code generator generates the random data with the use of date and time. The code generator obtains a bit pattern that cannot be specified by a person different from the genuine manufacturer. 
     While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore various omissions and substitutions and changes in the form of methods and systems described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirits of the inventions.