Patent Description:
Some of existing electrophotographic color image forming apparatuses have a configuration using an intermediate transfer method in which a toner image is sequentially transferred from an image forming unit of each color to an intermediate transfer member and, thereafter, the toner images are transferred from the intermediate transfer member to a transfer medium in one go.

In image forming apparatuses having such a configuration, the image forming unit of each color includes a drum-shaped photoconductive member (hereinafter referred to as a "photoconductive drum) serving as an image bearing member. As the intermediate transfer member, an intermediate transfer belt in the form of an endless belt is widely used. A toner image formed on the photoconductive drum of each of the image forming units is primarily transferred onto the intermediate transfer belt by applying a voltage from a primary transfer power source to a primary transfer member, which is provided so as to face the photoconductive drum via the intermediate transfer belt. The color toner images primarily transferred from the image forming units of the colors to the intermediate transfer belt are secondarily transferred from the intermediate transfer belt to a transfer medium, such as a paper sheet or an OHP sheet, in one go by applying a voltage from the secondary transfer power source to the secondary transfer member in a secondary transfer portion. Secondary transfer is performed on the transfer medium. Subsequently, the toner images of the respective colors transferred to the transfer medium are fixed onto the transfer medium by a fixing unit.

In the image forming apparatus of an intermediate transfer type, toner (residual transfer toner) remains on the intermediate transfer belt after a toner image is secondarily transferred from the intermediate transfer belt to a transfer medium. Accordingly, the residual transfer toner needs to be removed from the intermediate transfer belt before a toner image corresponding to the next image is primarily transferred to the intermediate transfer belt.

As a cleaning method for removing the transfer residual toner, a blade cleaning method is widely used. According to the blade cleaning method, the transfer residual toner is scraped off and collected into a cleaning container by a cleaning blade that is disposed downstream of the secondary transfer portion in the movement direction of the intermediate transfer belt and that is in contact with the intermediate transfer belt. In general, an elastic body, such as urethane rubber, is used as a cleaning blade. The cleaning blade is normally disposed such that an edge portion of the cleaning blade is in pressure contact with the intermediate transfer belt in a direction opposite to the movement direction of the intermediate transfer belt (a counter direction).

<CIT> describes a configuration in which the intermediate transfer belt has, on a surface thereof, grooves extending in the movement direction of the intermediate transfer belt in order to prevent wear of the cleaning blade. In the configuration, by reducing the contact area between the cleaning blade and the intermediate transfer belt, the friction coefficient between the cleaning blade and the intermediate transfer belt is reduced and, thus, wear of the cleaning blade is prevented.

The durability of the cleaning blade can be increased by using the configuration described in <CIT>. However, if the image forming apparatus is used for a longer period of time, it is required that the durability of the cleaning blade be increased more to prevent the occurrence of faulty cleaning.

As further prior art there may be mentioned <CIT>, which discloses an image forming apparatus employing an electrophotographic process in which a toner image formed on a photosensitive body is primarily transferred to an intermediate transfer body, and thereafter a secondary transfer is provided on a transfer medium, <CIT>, which discloses an electrophotographic copier in which a toner image formed on a photoreceptor is transferred to the outer surface of the photoreceptor itself, and then retransferred to a copy paper, <CIT>, which discloses an image forming apparatus constituted so that the Vickers hardness of the surface of the intermediate transfer member is larger than that of the surface of the image carrier, and wherein the surface roughness of the intermediate transfer member is larger than that of an initial photoreceptor drum, <CIT>, which discloses an image forming apparatus having an intermediate transfer belt that does not cause missing characters in primary transfer, <CIT>, which discloses an electrophotographic intermediate transfer method in which intermediate transfer is performed using an electrophotographic intermediate transfer belt containing a nitrogen element on its surface, wherein the electrophotographic intermediate transfer belt is coated with a metallic soap, and <CIT>, which discloses an image forming apparatus configured to include an intermediate transfer belt to which a toner imager is transferred from an image carrier, wherein the intermediate transfer belt has an elastic surface layer having a center point average roughness of <NUM> times or more of a volume average particle size of a used toner and a ten-point average roughness of not more than the volume average particle size of the used toner, and a development section which develops an electrostatic latent image on the image carrier by using a toner having a shape factor SF-<NUM> in the range of from <NUM> to <NUM> and a shape factor SF-<NUM> in the range of from <NUM> to <NUM>.

Accordingly, the present invention provides a configuration that collects residual toner on an intermediate transfer member by a contact member in contact with the intermediate transfer member to increase the durability of the contact member and prevent the occurrence of faulty cleaning.

The present invention in its first aspect provides an image forming apparatus as specified in claims <NUM> to <NUM>.

Exemplary embodiments of the present invention are described below with reference to the accompanying drawings. Note that constituent elements of the exemplary embodiments are very flexible in size, material, shape and relative positional relationship and should be changed in accordance with the configuration and various conditions of the apparatus of the invention. Thus, the following embodiments are not intended to limit the scope of the present invention in any way.

<FIG> is a schematic cross-sectional view of the configuration of an image forming apparatus <NUM> according to the present exemplary embodiment. The image forming apparatus <NUM> according to the present exemplary embodiment is what is called tandem type image forming apparatus provided with a plurality of image forming units a to d. The first image forming unit a forms an image by using yellow (Y) toner, the second image forming unit b forms an image by using magenta (M) toner, the third image forming unit c forms an image by using cyan (C) toner, and the fourth image forming unit d forms an image by using black (Bk) toner. These four image forming units are arranged in a line at regular intervals, and the four image forming units have substantially the same configuration except for the color of the toner to be stored. For this reason, the image forming apparatus <NUM> according to the present exemplary embodiment is described below with reference to the first image forming unit a.

The first image forming unit a includes a photoconductive drum 1a which is a drum-shaped photoconductive member, a charging roller 2a which is a charging member, a developing unit 4a, and a drum cleaning unit 5a.

The photoconductive drum 1a is an image bearing member that bears a toner image and is driven to rotate in a direction indicated by an arrow R1 in <FIG> at a predetermined process speed (<NUM>/sec according to the present exemplary embodiment). The developing unit 4a includes a developer container 41a for storing yellow toner and a development roller 42a which is a developing member. The development roller 42a bears the yellow toner stored in the developer container 41a and develops a yellow toner image on the photoconductive drum 1a. The drum cleaning unit 5a is a unit for collecting the toner adhering to the photoconductive drum 1a. The drum cleaning unit 5a includes a cleaning blade that is in contact with the photoconductive drum 1a and a waste toner box that stores, for example, toner removed from the photoconductive drum 1a by the cleaning blade.

When a control unit (not illustrated) receives an image signal, an image forming operation is started, and the photoconductive drum 1a is driven to rotate. During rotation, the photoconductive drum 1a is uniformly charged to a predetermined potential (a charging potential) with a predetermined polarity (a negative polarity according to the present exemplary embodiment) by the charging roller 2a and, thereafter, is exposed to light according to the image signal by the exposure unit 3a. In this way, an electrostatic latent image corresponding to the yellow component image of a target color image is formed. Subsequently, the electrostatic latent image is developed by the developing unit 4a at a development position and is visualized as a yellow toner image (hereinafter simply referred to as a "toner image"). At this time, the normal charging polarity of the toner stored in the developing unit 4a is negative. According to the present exemplary embodiment, an electrostatic latent image is developed using discharged area development, with the toner charged to the same polarity as the charging polarity of the photoconductive drum by the charging member. However, the present invention is applicable to the image forming apparatus that develops an electrostatic latent image by using charged area development, with toner charged to a polarity opposite to the charging polarity of the photoconductive drum.

An intermediate transfer belt <NUM> (intermediate transfer member), which is an endless movable intermediate transfer member, is disposed at a position so as to be in contact with the photoconductive drums 1a to 1d of the image forming units a to d, respectively. The intermediate transfer belt <NUM> is stretched around three axes of a support roller <NUM>, a tension roller <NUM>, and a facing roller <NUM>, which serve as stretching members. The intermediate transfer belt <NUM> is maintained in tension by a tension roller <NUM> with a total pressure of 60N. The intermediate transfer belt <NUM> moves in the direction indicated by arrow R2 due to the rotation of the facing roller <NUM> that rotates in accordance with a received driving force. The intermediate transfer belt <NUM> according to the present exemplary embodiment has a plurality of layers (described in more detail below).

When the toner image passes through a primary transfer portion N1a at which the photoconductive drum 1a is in contact with the intermediate transfer belt <NUM>, a voltage with a positive polarity is applied from a primary transfer power source <NUM> to the primary transfer roller 6a and, thus, the toner image formed on the photoconductive drum 1a is primarily transferred onto the intermediate transfer belt <NUM>. Subsequently, the residual toner that is not primarily transferred to the intermediate transfer belt <NUM> and remains on the photoconductive drum 1a is collected by the drum cleaning unit 5a. In this manner, the residual toner is removed from the surface of the photoconductive drum 1a.

Note that the primary transfer roller 6a is a primary transfer member (a touching member) that is provided at a position corresponding to the photoconductive drum 1a via the intermediate transfer belt <NUM> and that is in contact with the inner peripheral surface of the intermediate transfer belt <NUM>. The primary transfer power source <NUM> is a power source capable of applying a voltage with a positive or negative polarity to the primary transfer rollers 6a to 6d. While the present exemplary embodiment is described with reference to a configuration in which a voltage is applied from a shared primary transfer power source <NUM> to a plurality of primary transfer members, the present invention is not limited thereto. The present invention can be applied to a configuration in which a plurality of primary transfer power sources are provided corresponding to the primary transfer members.

Thereafter, in the same manner, a second magenta toner image, a third cyan toner image, and a fourth black toner image are formed and sequentially transferred onto the intermediate transfer belt <NUM> on top of another. As a result, the four color toner images corresponding to the target color image is formed on the intermediate transfer belt <NUM>. Subsequently, when the four color toner images born by the intermediate transfer belt <NUM> pass through a secondary transfer portion formed by contact of the secondary transfer roller <NUM> with the intermediate transfer belt <NUM>, the four color toner images are secondarily transferred onto a surface of a transfer medium P, such as a paper sheet or an OHP sheet, fed by a sheet feeding unit <NUM> in one go.

The secondary transfer roller <NUM> has an outer diameter of <NUM> and is formed by covering a nickel-plated steel rod having an outer diameter of <NUM> with a foamed sponge body mainly composed of NBR and epichlorohydrin rubber and having an adjusted volume resistivity of <NUM><NUM> Ω·cm and an adjusted thickness of <NUM>. Note that the rubber hardness of the foamed sponge body was measured by using Asker hardness meter type C, and the hardness was <NUM>° when loaded with <NUM>. The secondary transfer roller <NUM> is in contact with the outer circumferential surface of the intermediate transfer belt <NUM>, and a pressure of 50N is applied to the facing roller <NUM> disposed at a position facing the secondary transfer roller <NUM> via the intermediate transfer belt <NUM>. Thus, a secondary transfer portion N2 is formed.

The secondary transfer roller <NUM> is driven to rotate by the revolution of the intermediate transfer belt <NUM>. When a voltage is applied from a secondary transfer power source <NUM> to the secondary transfer roller <NUM>, a current flows from the secondary transfer roller <NUM> toward the facing roller <NUM>. As a result, the toner image born by the intermediate transfer belt <NUM> is secondarily transferred to the transfer medium P in the secondary transfer portion. Note that when the toner image on the intermediate transfer belt <NUM> is secondarily transferred to the transfer medium P, the voltage applied from the secondary transfer power source <NUM> to the secondary transfer roller <NUM> is controlled such that the current flowing from the secondary transfer roller <NUM> to the facing roller <NUM> via the intermediate transfer belt <NUM> is constant. In addition, the magnitude of the current for performing the secondary transfer is determined in advance in accordance with the surrounding environment in which the image forming apparatus <NUM> is installed and the type of the transfer medium P. The secondary transfer power source <NUM> is connected to the secondary transfer roller <NUM> and applies a transfer voltage to the secondary transfer roller <NUM>. The secondary transfer power source <NUM> can output a voltage in the range of <NUM> (V) to <NUM> (V).

Subsequently, the transfer medium P having the four color toner images transferred thereon through secondary transfer is heated and pressurized in a fixing unit <NUM>. Thus, the four color toner particles are melted and mixed. The melted toner is fixed to the transfer medium P. The toner remaining on the intermediate transfer belt <NUM> after the secondary transfer is cleaned or removed by a belt cleaning unit <NUM> (a collection unit) provided downstream of the secondary transfer portion N2 in the movement direction of the intermediate transfer belt <NUM>. The belt cleaning unit <NUM> includes a cleaning blade 16a serving as a contact member that is in contact with the outer circumferential surface of the intermediate transfer belt <NUM> at a position facing the facing roller <NUM>, a waste toner container 16b that stores the toner collected by the cleaning blade 16a. Hereinafter, the cleaning blade 16a is simply referred to as a "blade 16a".

In the image forming apparatus <NUM> according to the present exemplary embodiment, a full-color print image is formed through the above-described operation. Belt Cleaning Unit.

<FIG> is a schematic illustration of the blade 16a in contact with the intermediate transfer belt <NUM>, and <FIG> is an enlarged schematic illustration of a contact portion between the blade 16a and the intermediate transfer belt <NUM>. According to the present exemplary embodiment, the blade 16a is a plate-like member having a long side extending in the width direction of the intermediate transfer belt <NUM> (hereinafter referred to as a "belt width direction") that crosses the movement direction of the intermediate transfer belt <NUM> (hereinafter referred to as a "belt conveyance direction").

According to the present exemplary embodiment, the blade 16a has an elastic portion <NUM> that is in contact with the intermediate transfer belt <NUM> and that scrapes off the toner and a sheet metal portion <NUM> (a support portion) that supports the elastic portion <NUM>. The elastic portion <NUM> is a blade member made of polyurethane. One end in the short direction of the elastic portion <NUM> is fixed to the sheet metal portion <NUM>, and the other end is a free end that is in free contact with the intermediate transfer belt <NUM>. More specifically, the blade 16a has a blade shape and includes the elastic portion <NUM> that is in contact with the intermediate transfer belt <NUM>. The width of the elastic portion <NUM> is <NUM>. The elastic portion <NUM> is bonded to the sheet metal portion <NUM> to form the blade 16a. The length of the elastic portion <NUM> of the blade 16a (in the belt width direction) is <NUM>, and the thickness of the elastic portion <NUM> is <NUM>. A free length, which is a length from a bonding point with the sheet metal portion <NUM>, is <NUM>. The hardness of the blade 16a is <NUM> degrees defined by JIS K <NUM> standard.

The facing roller <NUM> is disposed adjacent to the inner periphery of the intermediate transfer belt <NUM> so as to face the blade 16a. The blade 16a is in contact with the surface of the intermediate transfer belt <NUM> at a position facing the facing roller <NUM> so as to be directed in the counter direction (a direction opposite to the belt conveyance direction). That is, the blade 16a is in contact with the surface of the intermediate transfer belt <NUM> such that the free end is directed upstream in the belt conveyance direction. Thus, as illustrated in <FIG>, a blade nip portion Nb (a contact portion) is formed between the blade 16a and the intermediate transfer belt <NUM>. The blade 16a scrapes off toner on the surface of the moving intermediate transfer belt <NUM> at the blade nip portion Nb and collects the toner into the waste toner container 16b. According to the present exemplary embodiment, the width of the blade nip portion Nb where the blade 16a and the intermediate transfer belt <NUM> are in contact with each other in the belt conveyance direction is <NUM>.

According to the configuration of the present exemplary embodiment, as illustrated in <FIG>, since the blade 16a is disposed so as to be directed in the counter direction, the tip portion of the blade 16a that is in contact with the intermediate transfer belt <NUM> receives a frictional force in the belt conveyance direction. The frictional force received by the tip of the blade 16a is a force in a direction in which the tip of the blade 16a is bent, following the intermediate transfer belt <NUM> moving in the belt conveyance direction. As a result, as illustrated in <FIG>, the contact portion of the blade 16a is curved due to the frictional force at the contact portion, and the blade 16a is caught in the intermediate transfer belt <NUM>. A portion of the blade 16a that is tucked in at this time is defined as the tuck portion M, and the distance (the length) of the tuck portion M in the belt conveyance direction is defined as an "tuck amount m". Furthermore, as illustrated in <FIG>, let's suppose that when the blade 16a is brought into contact with the intermediate transfer belt <NUM> and is pushed by the intermediate transfer belt <NUM>, the blade 16a is not deformed at all and intrudes into the facing roller <NUM>. Then, the depth (the length) of part of the tip surface of the blade 16a that intrudes into the facing roller <NUM> measured in the tip surface direction is defined as an intrusion amount δ.

According to the present exemplary embodiment, the blade 16a is disposed relative to the intermediate transfer belt <NUM> such that a setting angle θ is <NUM>°, the intrusion amount δ is <NUM>, and the contact pressure is <NUM> N. As used herein, the setting angle θ refers to an angle formed by the tangent line to the facing roller <NUM> at the intersection of the intermediate transfer belt <NUM> and the blade 16a (more specifically, the end surface of the free end) and the blade 16a (more specifically, one surface of the blade 16a that is perpendicular to the thickness direction). Furthermore, the intrusion amount δ is the length of an overlapping portion between the blade 16a and the facing roller <NUM> in the thickness direction. The contact pressure is defined by the pressing force (linear pressure in the longitudinal direction) exerted by the blade 16a at the blade nip portion Nb. The contact pressure is measured by using a film pressure measurement system (Trade Name: PINCH available from Nitta Corporation).

Note that the blade 16a blocks the toner remaining on the intermediate transfer belt <NUM> by applying a pressure to the intermediate transfer belt <NUM> by the tuck portion M of the blade 16a which is tucked in by the frictional force between the blade 16a and the intermediate transfer belt <NUM>. Thereafter, the toner blocked by the blade 16a is collected into the waste toner container 16b. Thus, in order to ensure toner collectability, the blade 16a is in pressure contact with the intermediate transfer belt <NUM> at a predetermined pressure so as to prevent the toner from slipping through.

However, if the pressure of the blade 16a against the intermediate transfer belt <NUM> is too high, the frictional force applied to the tip of the blade 16a increases and, thus, the tuck amount m of the tuck portion M of the blade 16a increases. If the tuck amount m becomes too large, complete tuck may occur. The blade 16a that is in contact with the intermediate transfer belt <NUM> while being directed in the counter direction may be in contact with the intermediate transfer belt <NUM> while being directed in the belt conveyance direction (hereinafter referred to as "turn-over"). If the turn-over occurs, it becomes difficult to block the toner remaining on the intermediate transfer belt <NUM> by the blade 16a, resulting in faulty cleaning. For this reason, to ensure the collectability of the toner remaining on the intermediate transfer belt <NUM>, it is necessary to appropriately set the tuck amount m of the blade 16a.

As a method for adjusting the tuck amount m of the blade 16a, a method is developed for adjusting the dynamic friction coefficient of the intermediate transfer belt <NUM> and controlling the frictional force applied to the tuck portion M of the blade 16a. For example, the surface of the intermediate transfer belt <NUM> is provided with a plurality of grooves or irregularities extending in the belt conveyance direction to reduce the contact area between the blade 16a and the intermediate transfer belt <NUM> and reduce the dynamic friction coefficient between the intermediate transfer belt <NUM> and the blade 16a. Thus, the frictional force can be reduced. In this manner, the tuck amount m of the blade 16a with respect to the intermediate transfer belt <NUM> can be controlled. Alternatively, as a unit for adjusting the tuck amount m of the blade 16a, a method is developed for adjusting the frictional force applied to the tuck portion M of the blade 16a by previously applying a lubricant, such as fluorinated graphite, to the tip of the blade 16a.

The configuration of the intermediate transfer belt <NUM> according to the present exemplary embodiment is described below. <FIG> is a schematic illustration of the overall configuration of the intermediate transfer belt <NUM>. <FIG> is a schematic enlarged partial cross-sectional view of the intermediate transfer belt <NUM> in a region X of <FIG> when the intermediate transfer belt <NUM> is cut in a direction substantially perpendicular to the belt conveyance direction (as viewed in the belt conveyance direction). <FIG> is an enlarged partial cross-sectional view of <FIG> and illustrates a surface layer <NUM> of the intermediate transfer belt <NUM> (described below) in more detail. <FIG> is a schematic enlarged partial cross-sectional view of the intermediate transfer belt <NUM> in a region Y of <FIG> when the intermediate transfer belt <NUM> is cut in a direction substantially perpendicular to the belt conveyance direction (as viewed in the belt conveyance direction). <FIG> is an enlarged partial cross-sectional view of <FIG> and illustrates the surface layer <NUM> of the intermediate transfer belt <NUM> in more detail.

The intermediate transfer belt <NUM> is an endless belt member (or an endless film-like member) composed of two layers, a base layer <NUM> and the surface layer <NUM>. The circumferential length of the intermediate transfer belt <NUM> is <NUM>, and the longitudinal width in the belt width direction is <NUM>. As used herein, the term "base layer" refers to the thickest one of the layers that constitute the intermediate transfer belt <NUM> with respect to the thickness direction of the intermediate transfer belt <NUM>. According to the present exemplary embodiment, the base layer <NUM> is made of polyethylene naphthalate resin containing dispersed quaternary ammonium salt, which is an ionic conductive agent serving as an electrical resistance adjusting agent. The base layer <NUM> is <NUM> in thickness.

Note that the material of the base layer <NUM> is not limited to the above-described one. For example, instead of polyethylene naphthalate resin, the base layer <NUM> may be made of a thermoplastic resin. Examples of a thermoplastic resin include polycarbonate, polyvinylidene fluoride (PVDF), polyethylene, polypropylene, polymethylpentene-<NUM>, polystyrene, polyamide, polysulfone, polyarylate, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polyphenylene sulfide, polyethersulfone, polyethernitrile, thermoplastic polyimide, polyetheretherketone, thermotropic liquid crystal polymer, and polyamide acid. Two or more of these can be mixed and used. Moreover, as an ionic conductive agent added to the base layer <NUM>, ionic liquid, a conductive oligomer, or a quaternary ammonium salt can be used, for example. One or more of these conductive materials may be appropriately selected and used. Alternatively, an electronic conductive material and an ion conductive material may be mixed and used.

The surface layer <NUM> is a layer that forms the outer circumferential surface of the intermediate transfer belt <NUM>. The surface layer <NUM> according to the present embodiment is obtained by dispersing antimony-doped zinc oxide, which serves as an electrical resistance adjusting agent <NUM>, in an acrylic resin which forms a base material <NUM>, and polytetrafluoroethylene (PTFE) particles, which are fluorine-containing particles, are added to the acrylic resin as the solid lubricant <NUM>. The surface layer <NUM> is <NUM> in thickness.

Other than an acrylic resin, an example of an organic base material <NUM> of the surface layer <NUM> is a cured resin, such as a melamine resin, a urethane resin, an alkyd resin, and a fluorine-type cured resin (fluorine-containing cured resin). Examples of an inorganic material include alkoxysilane/alkoxyzirconium-based materials and silicate-based materials. Examples of an organic/inorganic hybrid material include inorganic fine particle-dispersed organic polymer materials, inorganic fine particle-dispersed organoalkoxysilane materials, acrylic silicon materials, and organoalkoxysilane materials.

In addition, an example of the conductive agent added to the surface layer <NUM> is a particulate, fibrous, or flaky carbon-based conductive filler, such as carbon black, PAN-based carbon fiber, or expanded graphite pulverized product. Alternatively, for example, particulate, fibrous or flaky metallic conductive filler, such as silver, nickel, copper, zinc, aluminum, stainless steel, or iron, can be used. Still alternatively, for example, a particulate metal oxide conductive filler, such as zinc antimonate, antimony-doped tin oxide, antimony-doped zinc oxide, tin-doped indium oxide, or aluminum-doped zinc oxide, can be used.

From the viewpoint of strength, such as wear resistance or crack resistance, the surface layer <NUM> is preferably a resin material (a cured resin) among cured materials. Among the cured resins, an acrylic resin obtained by curing an unsaturated double bond-containing acrylic copolymer is more preferable. According to the present exemplary embodiment, the surface layer <NUM> of the intermediate transfer belt <NUM> is achieved by applying liquid containing ultraviolet curable monomer and/or oligomer component to the surface of the base layer <NUM> and, thereafter, emitting an energy ray, such as ultraviolet ray, to cure the liquid.

According to the present exemplary embodiment, the volume resistivity of the intermediate transfer belt <NUM> is <NUM> × <NUM><NUM> Ω·cm. The volume resistivity was measured with a UR probe (model MCP-HTP12) connected to Hiresta-UP (MCP-HT450) available from Mitsubishi Chemical Corporation, with an applied voltage of 100V and a measurement time of <NUM> seconds. The environment of a measurement chamber for measuring the volume resistivity was set to a temperature of <NUM> and a humidity of <NUM>%, and the intermediate transfer belt <NUM> was placed in the environment for four hours. Thereafter, the volume resistivity of the intermediate transfer belt <NUM> was measured.

As illustrated in <FIG> and <FIG>, the intermediate transfer belt <NUM> according to the present exemplary embodiment has a region X (a first region) and a region Y (a second region) in which the surface layer <NUM> is subjected to a surface processing treatment in order to prevent wear of the blade 16a. The surface processing is carried out on an area defined by a width greater than or equal to the width of the blade 16a and the entire length extending in the belt conveyance direction. In addition, as illustrated in <FIG>, the intermediate transfer belt <NUM> has a first switching point at which the region X is changed to the region Y in the belt conveyance direction and a second switching point at which the region Y is changed to the region X. That is, the intermediate transfer belt <NUM> has the single region X that is formed continuously in the belt conveyance direction and the single region Y that is formed continuously in the belt conveyance direction. In the following description, with respect to the belt conveyance direction, the distance from the first switching position to the second switching position is defined as a distance of the region Y, and the distance from the second switching position to the first switching position is defined as a distance of the region X. According to the present exemplary embodiment, the distance of the region Y is <NUM>, and the distance of the region X is <NUM>.

According to the present exemplary embodiment, as illustrated in <FIG>, a plurality of grooves (groove shapes or groove portions) <NUM> that extend in the belt conveyance direction are formed in the region X and the region Y so as to be arranged in the belt width direction. An interval K1 between the grooves <NUM> in the region X is <NUM>, and an interval K2 between the grooves <NUM> in the region Y is <NUM> (described in more detail below). According to the configuration, the intermediate transfer belt <NUM> according to the present exemplary embodiment has a dynamic friction coefficient that is smaller in the region Y than in the region X.

The configuration of the grooves <NUM> formed in the region X and the region Y of the intermediate transfer belt <NUM> is described with reference to <FIG>. In the following description, the shape of the groove <NUM> was measured by using L-trace & NanoNaviII (available from SII Nanotechnology Inc. The measurement was carried out in the DFM mode using the high-aspect probe SI-<NUM> as the cantilever.

As illustrated in <FIG>, in the region X, a width W1 of an opening portion of the groove <NUM> in the belt width direction (hereinafter simply referred to as a "width W1") is <NUM>. In addition, a depth d from a surface of the surface layer <NUM> with no groove (the opening portion) to the bottom of the groove <NUM> in the thickness direction of the intermediate transfer belt <NUM> (hereinafter simply referred to as a "depth d") is <NUM>. The interval K1 between the grooves <NUM> in the belt width direction is <NUM>. Note that according to the present exemplary embodiment, the groove shapes illustrated in <FIG> are formed in the region X of the intermediate transfer belt <NUM> by pressing a columnar die having convex portions formed at intervals of <NUM> against the surface layer <NUM> and rotating the die.

Subsequently, as illustrated in <FIG>, in the region Y, a width W2 of the opening portion of the groove <NUM> in the belt width direction (hereinafter simply referred to as a "width W2") is <NUM>, as in the region X. In addition, as in the region X, a depth d from a surface of the surface layer <NUM> with no groove (the opening portion) to the bottom of the groove <NUM> in the thickness direction of the intermediate transfer belt <NUM> (hereinafter simply referred to as a "depth d") is <NUM>. Unlike the region X, in the region Y, an interval K2 between the grooves <NUM> in the belt width direction is set to <NUM>, which is smaller than the interval K1 in the region X. Note that according to the present exemplary embodiment, the groove shapes illustrated in <FIG> are formed in the region Y of the intermediate transfer belt <NUM> by pressing a columnar die having convex portions formed at intervals of <NUM> against the surface layer <NUM> and rolling the die.

The width W1 and width W2 of the grooves <NUM> are preferably about half the average particle diameter of the toner, from a cleaning performance perspective. If the width W1 and the width W2 of the groove <NUM> are too large, toner particles may enter the grooves <NUM> and, thus, slip through the blade nip portion Nb, resulting in faulty cleaning. However, if the width W1 and the width W2 of the groove <NUM> are too small, the contact area between the blade 16a and the intermediate transfer belt <NUM> becomes too large, resulting in increased friction at the blade nip portion Nb and increased wear of the tip of the blade 16a. For this reason, according to the configuration of the present exemplary embodiment, the width W1 and the width W2 of the groove <NUM> are preferably set to a value greater than or equal to <NUM> and less than or equal to <NUM>.

According to the present exemplary embodiment, since the surface layer <NUM> is <NUM> in thickness, the groove <NUM> does not reach the base layer <NUM> but exists only in the surface layer <NUM>. In addition, <NUM> of the grooves <NUM> are substantially continuously formed on the intermediate transfer belt <NUM> in the circumferential direction (the rotational direction) of the intermediate transfer belt <NUM>.

Note that according to the present exemplary embodiment, the grooves <NUM> in the region X and the grooves <NUM> in the region Y are formed by using the columnar dice having the convex portions formed thereon at different intervals. However, the dice are not limited thereto. Even when the interval between the convex portions for the region Y is the same as that for the region X, the grooves <NUM> in the region Y may be formed by using a columnar die having convex portions formed obliquely with respect to the rotation direction of the cylinder and pressing the die against only the region Y and rolling the die around the entire region Y twice. That is, by pressing the columnar die for the first round in the circumferential direction of the intermediate transfer belt <NUM> and, thereafter, continuously pressing the columnar die against only the region Y of the intermediate transfer belt <NUM> for the second round, the grooves <NUM> are formed on the surface layer <NUM> having the previously formed grooves <NUM> in an overlapping manner. As a result, the grooves <NUM> can be formed in the region Y at intervals smaller than those in the region X. Thus, the intermediate transfer belt <NUM> having different dynamic friction coefficients for the region X and the region Y can be obtained.

Alternatively, instead of using a columnar die having obliquely formed convex portions, a columnar die having convex portions each formed in parallel to the circumferential direction may be obliquely pressed against the surface layer <NUM> of the intermediate transfer belt <NUM>, and the region X and the region Y may be formed. Even in this case, by pressing the columnar die obliquely for the first round in the circumferential direction of the intermediate transfer belt <NUM> and, thereafter, continuously pressing the columnar die against only the region Y of the intermediate transfer belt <NUM> for the second round, the grooves <NUM> are formed on the surface layer <NUM> having the previously formed grooves <NUM> in an overlapping manner. As a result, the grooves <NUM> can be formed in the region Y at intervals smaller than those in the region X. Thus, the intermediate transfer belt <NUM> having different dynamic friction coefficients for the region X and the region Y can be obtained.

At this time, the thickness of the surface layer <NUM> needs to be greater than or equal to the thickness at which the groove <NUM> can be formed, that is, the depth d of the groove <NUM>. If the thickness of the surface layer <NUM> is smaller than the depth d of the groove <NUM>, the groove <NUM> reaches the base layer <NUM> and, thus, a substance added to the base layer <NUM> may be deposited on the surface of the surface layer <NUM>. Consequently, faulty cleaning may occur. In contrast, if the thickness of the surface layer <NUM> is too large, the surface layer <NUM> made of an acrylic resin may be cracked, which causes faulty cleaning. For this reason, according to the configuration of the present exemplary embodiment, the thickness of the surface layer <NUM> is preferably set to a value greater than or equal to <NUM> and less than or equal to <NUM> and is more preferably set to a value greater than or equal to <NUM> and less than or equal to <NUM> in consideration of cracking in the surface layer <NUM> during long-term use.

As described above, according to the present exemplary embodiment, the contact area between the blade 16a and the intermediate transfer belt <NUM> is controlled by forming the grooves <NUM> in the region X and the region Y of the intermediate transfer belt <NUM> at different intervals. In this manner, the dynamic friction coefficient between the blade 16a and the intermediate transfer belt <NUM> is controlled to control the force applied to the tuck portion M of the blade 16a. Thus, wear of the blade 16a can be prevented. According to the present exemplary embodiment, the grooves <NUM> are formed in an area wider than the width of the blade 16a in the belt width direction. That is, the intermediate transfer belt <NUM> has a configuration in which the width of the region X and the region Y is greater than the width of the blade 16a in the belt width direction. In this way, wear of the blade 16a can be stably prevented over the entire width of the blade 16a.

As illustrated in <FIG>, the intermediate transfer belt <NUM> of the present exemplary embodiment has the region X having the grooves <NUM> formed in the surface layer <NUM> at intervals of <NUM> and a region Y having the grooves <NUM> formed at intervals of <NUM>. Since the contact area between the blade 16a and the intermediate transfer belt <NUM> is larger in the region X than in the region Y, the frictional force between the blade 16a and the intermediate transfer belt <NUM> increases. As a result, the tuck portion M increases. In contrast, since the interval between the grooves <NUM> is small in the region Y, the contact area between the blade 16a and the intermediate transfer belt <NUM> decreases. In addition, the surface area of the intermediate transfer belt <NUM> increases. Consequently, an area in which the solid lubricant <NUM> is exposed increases. As a result, the dynamic friction coefficient between the blade 16a and the intermediate transfer belt <NUM> decreases in the region Y, as compared with the region X.

Table <NUM> presents comparison of the dynamic friction coefficients of the region X and the region Y and comparison of the magnitudes of the tuck amount m in the region X and the region Y The dynamic friction coefficient and the tuck amount m corresponding to the region X were measured by using an intermediate transfer belt having the grooves <NUM> formed on the entire surface in the belt conveyance direction at intervals K1 (an intermediate transfer belt having only the region X). In addition, the dynamic friction coefficient and the tuck amount m corresponding to the region Y were measured by using an intermediate transfer belt having the grooves <NUM> formed on the entire surface in the belt conveyance direction at intervals K2 (an intermediate transfer belt having only the region Y).

The dynamic friction coefficient was measured using a surface property tester ("HEIDON 14FW" available from Shinto Scientific Co. In the measurement, an urethane rubber ball indenter (with an outer diameter of <NUM>/<NUM> inch and a rubber hardness of <NUM> degrees) was used as a measurement indenter. The measurement conditions included a test load of <NUM> gf, a speed of <NUM>/sec, and a measurement distance of <NUM>. The values of the dynamic friction coefficient in Table <NUM> were obtained by dividing the average of the frictional forces (gf) measured in <NUM> second to <NUM> seconds from the start of measurement by the test load (gf).

In addition, the magnitude of the tuck amount m of the blade 16a was measured as follows. The blade 16a with a tip portion having fluorinated graphite applied thereto was installed for the intermediate transfer belt <NUM> first. Thereafter, the image forming apparatus was operated for <NUM> minutes in a non-image forming mode, and the blade 16a was removed from the image forming apparatus. The tip portion of the blade 16a was observed with a microscope. Subsequently, the width of a portion where fluorinated graphite applied to the tip portion of the blade 16a was peeled off by rubbing against the intermediate transfer belt <NUM> was measured. The obtained width represents the tuck amount m.

As can be seen from Table <NUM>, in the region Y where the dynamic friction coefficient is smaller than in the region X, the tuck amount m is also smaller. That is, according to the intermediate transfer belt <NUM> having the region X with the first dynamic friction coefficient and the region Y with the second dynamic friction coefficient which is smaller than the first dynamic friction coefficient, the tuck amount m of the blade 16a in the blade nip portion Nb can be changed.

<FIG> is a schematic enlarged cross-sectional view of the blade 16a in contact with the region X in the blade nip portion Nb. <FIG> is a schematic enlarged cross-sectional view of the blade 16a in contact with the region Y after the blade 16a has passed the first switching position due to the movement of the intermediate transfer belt <NUM>. <FIG> is a schematic enlarged cross-sectional view of the blade 16a in contact with the region X again after the blade 16a has passed the second switching position due to the movement of the intermediate transfer belt <NUM>.

When the blade 16a passes through the region X, the tuck portion M of the blade 16a has a shape illustrated in <FIG> due to friction between the blade 16a and the region X. As illustrated in <FIG>, when the intermediate transfer belt <NUM> revolves, the blade 16a passes through the first switching position and is brought into contact with the region Y As can be seen from Table <NUM>, the dynamic friction coefficient in the region X differs from in the region Y, and the dynamic friction coefficient is reduced at the first switching position at which the region X is switched to the region Y Then, as illustrated in <FIG>, the tuck portion M of the blade 16a is deformed, and the tuck amount m decreases. Thereafter, when the intermediate transfer belt <NUM> further moves and the blade 16a passes through the second switching position and is brought into contact with the region X again, the shape of the tuck portion M returns to it's original shape illustrated in <FIG>, as illustrated in <FIG>.

As described above, when the blade 16a passes through the first switching position and the second switching position, the shape of the tuck portion M of the blade 16a changes and, thus, the tuck amount m changes. As a result, as illustrated in <FIG>, the contact condition between the blade 16a and the intermediate transfer belt <NUM> can be changed as the intermediate transfer belt <NUM> moves.

<FIG> is a schematic illustration of the force applied to the tuck portion M of the blade 16a when the blade 16a passes through the region X, and <FIG> is a schematic illustration of the force applied to the tuck portion M of the blade 16a when the blade 16a passes through the region Y As illustrated in <FIG>, when the blade 16a passes through the region X, a restoring force F1x of the blade 16a that attempts to restore the deformation of the tuck portion M and a frictional force F2x caused by the revolution of the intermediate transfer belt <NUM> are generated in the tuck portion M. At a position at which the restoring force F1x crosses the frictional force F2x, a stress concentration portion Px at which a shearing force exerted on the tuck portion M concentrates is formed. In addition, as illustrated in <FIG>, when the blade 16a passes through the region Y, a restoring force F1y of the blade 16a that attempts to restore the deformation of the tuck portion M and a frictional force F2y caused by the revolution of the intermediate transfer belt <NUM> are generated in the tuck portion M. At a position at which the restoring force F1y crosses the frictional force F2y, a stress concentration portion Py at which a shearing force exerted on the tuck portion M concentrates is formed.

In the configuration according to the present exemplary embodiment, by using the intermediate transfer belt <NUM> having the region X and the region Y having a dynamic friction coefficient smaller than in the region X, the tuck amount m of the tuck portion M of the blade 16a can be changed. As a result, as illustrated in <FIG>, in the region Y, the stress concentration portion Px of the blade 16a disappears, and the new stress concentration portion Py is formed. In this way, it is possible to prevent wear of the blade 16a in the stress concentration portion Px.

Note that according to the present exemplary embodiment, the distance of the region Y is set to be greater than the distance of the blade nip portion Nb and less than the distance of the region X in the belt conveyance direction. With respect to the belt conveyance direction, the entire area of the blade nip portion Nb is included in the region Y In this manner, the tuck amount m of the tuck portion M of the blade 16a can be changed, and the stress concentration portion Px of the blade 16a can be made disappear. Accordingly, the distance of the region Y needs to be set greater than the distance of the blade nip portion Nb in the belt conveyance direction.

Furthermore, if the distance of the area Y is greater than the distance of the area X in the belt conveyance direction, the area of the intermediate transfer belt <NUM> having a low dynamic friction coefficient is larger than the area having a high dynamic friction coefficient, so that the transfer residual toner is likely to pass through the nip portion for collection. As a result, faulty cleaning may occur. Such faulty cleaning easily occurs if the intermediate transfer belt <NUM> has a low dynamic friction coefficient and the amount of residual toner that reaches the blade nip portion Nb varies in the width direction of the blade 16a perpendicular to the belt conveyance direction. More specifically, if the amount of transfer residual toner that reaches the blade nip portion Nb varies in the width direction of the blade 16a in accordance with the image pattern at the time of image formation, the frictional force between the intermediate transfer belt <NUM> and the blade 16a may decrease locally. In this case, there is a possibility that the stress concentration portion Py disappears because the tuck amount m in the region Y is small. Thus, the tuck portion M of the blade 16a may be lifted, so that the blade nip portion Nb may locally disappear. At this time, faulty cleaning caused by slipping-through of the residual transfer toner may occur at the position where the blade nip portion Nb disappears. For this reason, it is desirable that the distance of the region Y be set to be less than the distance of the region X in the belt conveyance direction.

As described above, according to the configuration of the present exemplary embodiment, the occurrence of faulty cleaning can be reduced without increasing the cost of the image forming apparatus and without reducing the throughput of the image forming apparatus.

Note that it is desirable that the width in the belt width direction of the region Y be greater than the width of the blade 16a. This is because if the width of the region Y is greater than the width of the blade nip portion Nb, the entire blade 16a can be operated to move the tuck portion M greatly when passing through the first switching position.

Furthermore, according to the configuration of the present exemplary embodiment, the interval K2 between the grooves <NUM> in the region Y is <NUM>. However, the interval K2 is not limited to <NUM>. If the difference in dynamic friction coefficient between the blade 16a and the intermediate transfer belt <NUM> between the region X and the region Y is too large, a change in tuck amount m of the tuck portion M when the blade 16a passes the first switching position and the second switching position is large. In this case, slipping-through of the residual transfer toner may easily occur during the change in the tuck amount m. For this reason, it is desirable that the difference between the dynamic friction coefficient in the region X and that in the region Y be less than or equal to <NUM>.

The intervals K2 between the grooves <NUM> in the region Y are not necessarily equal, and it is only required that the average value in the range of <NUM>, which is the groove interval in a direction perpendicular to the extending direction of the grooves <NUM> in the region X, satisfy the above-described relationship regarding the difference between the dynamic friction coefficients.

Subsequently, the cleaning performance of the intermediate transfer belt <NUM> according to the present exemplary embodiment and the cleaning performance of an intermediate transfer belt of a comparative example in the image forming apparatus <NUM> were evaluated. In the comparative example, an intermediate transfer belt has no groove <NUM>, and a constant tuck amount is formed over the entire circumference of the intermediate transfer belt at all times.

To evaluate the cleaning performance, a durability test to form text images having a printing ratio of <NUM>% for each color in a two-page intermittent mode was carried out. In the test, an image was formed once every <NUM>,<NUM> letter size sheets (trade name "Vitality" available from Xerox Corporation) to determine whether faulty cleaning occurred. Note that the evaluation test was performed in an environment with a temperature of <NUM> and a humidity of <NUM>%.

To determine whether faulty cleaning occurred once every <NUM>,<NUM> sheets in the above-described durability test, the following technique was used. The output from the secondary transfer power source <NUM> was switched off (<NUM> V) first and, thereafter, a red solid image (a solid image of <NUM>% yellow and <NUM>% magenta) was formed. Subsequently, the output from the secondary transfer power source <NUM> is set to a proper value, and five sheets of transfer medium P not having an image formed thereon were continuously fed. That is, it was determined whether faulty cleaning occurred by determining whether residual toner not transferred to the transfer medium P for the red solid image at the secondary transfer portion N2 was removed by the blade 16a.

If the toner for the red solid image can be completely removed from the intermediate transfer belt <NUM>, the five sheets of transfer medium P that are continuously fed are output as substantially completely blank sheets. However, if the toner for the red solid image cannot be completely removed, the toner that has slipped through the blade 16a reaches the secondary transfer portion N2 again, so that the toner is transferred to the five sheets of transfer medium P that are continuously fed. Consequently, an image subjected to faulty cleaning is formed and output. The occurrence of faulty cleaning was monitored in the above-described manner once every <NUM>,<NUM> sheets of transfer medium P, and the evaluation was carried out for <NUM>,<NUM> sheets of transfer medium P in total.

As a result of evaluation of the cleaning performance, according to the configuration of the exemplary embodiment, faulty cleaning does not occur up to <NUM>,<NUM> sheets. In contrast, according to the configuration of the comparative example, faulty cleaning occurs after <NUM>,<NUM> sheets are fed.

When the tip portion of the cleaning blade used in the comparative example was observed with a microscope, the urethane rubber was worn by friction with the intermediate transfer belt <NUM>, and the cleaning blade was worn, starting from the vicinity of the middle point of the tuck portion. This is because the dynamic friction coefficient between the intermediate transfer belt <NUM> and the cleaning blade is large and, thus, the cleaning blade is easily worn at the tuck portion M.

As described above, according to the configuration of the present exemplary embodiment, the intermediate transfer belt <NUM> is used that has the region X and the region Y having a dynamic friction coefficient lower than that of the region X. Thus, the stress concentration portion Px of the tuck portion M formed in the blade 16a can be periodically made disappear. As a result, it is possible to prevent the occurrence of faulty cleaning while preventing the wear of the blade 16a and improving the durability.

According to the present exemplary embodiment, to change the dynamic friction coefficient of the intermediate transfer belt <NUM>, the process of forming the grooves <NUM> is performed on the surface layer <NUM> of the intermediate transfer belt <NUM>. However, the technique is not limited thereto. As another technique, for example, the surface layer <NUM> of the intermediate transfer belt <NUM> may be polished by using a polishing member, such as a lapping film, to change the polishing strengths. Alternatively, a process for forming grooves in one of the region X and the region Y and polishing the other may be performed. Still alternatively, the region X and the region Y may be polished by using lapping films having different roughnesses. More specifically, the region X of the surface layer <NUM> of the intermediate transfer belt <NUM> may be polished with a fine lapping film (Lapika #<NUM> (product name) available from KOVAX Corporation), and the region Y may be polished with a rough lapping film (Lapika #<NUM> (product name) available from KOVAX Corporation). When the surface is polished with a rough lapping film, the surface has a roughness higher than that polished with a fine lapping film. In addition, an exposed area of the solid lubricant increases and, thus, the dynamic friction coefficient of the surface can be decreased.

According to the present exemplary embodiment, as illustrated in <FIG>, the grooves <NUM> are formed in the region X and the region Y in parallel to the belt conveyance direction. However, the present invention is not limited thereto. The grooves <NUM> only need to extend in a direction crossing the width direction perpendicular to the movement direction of the intermediate transfer belt <NUM>. The grooves <NUM> may be formed at an angle with respect to the movement direction of the intermediate transfer belt <NUM>. However, to obtain the effect of reducing the dynamic friction coefficient between the intermediate transfer belt <NUM> and the blade 16a, an angle formed by the direction in which the groove <NUM> extends and the movement direction of the intermediate transfer belt <NUM> is preferably <NUM>° or less and is more preferably <NUM>° or less.

As another technique for changing the dynamic friction coefficients in the region X and the region Y, coating liquid containing lubricating particles may be sprayed over the region Y A spray application portion has a high surface roughness and increases the exposed area of the solid lubricant. In this way, the dynamic friction coefficient may be decreased.

According to the first exemplary embodiment, the configuration is described in which the dynamic friction coefficients in the region X and the region Y are changed by controlling the intervals K1 and K2 between the grooves <NUM> formed in the surface layer <NUM> of the intermediate transfer belt <NUM>. In contrast, according to the second exemplary embodiment, a configuration is described in which a width W1 of a groove <NUM> and a width W2 of a groove <NUM> formed in the surface layer <NUM> of the intermediate transfer belt <NUM> are controlled before and after the first switching position and before and after the second switching position to control the dynamic friction coefficients in the region X and the region Y Note that the configuration of the present exemplary embodiment is substantially the same as the configuration of the first exemplary embodiment except that the widths W1 and W2 of the grooves <NUM> are controlled. Accordingly, the same reference numerals are used in the present exemplary embodiment to describe those constituent elements that are identical to the constituent elements of the first exemplary embodiment, and description of the constituent elements are not repeated.

<FIG> is a schematic illustration of the interval K1 and the width W1 of the groove <NUM> in the region X according to the present exemplary embodiment, and <FIG> is a schematic illustration of the interval K1 and the width W1 of the groove <NUM> in the region Y according to the present exemplary embodiment. As illustrated in <FIG>, according to the present exemplary embodiment, the interval K1 between the grooves <NUM> in the region X is the same as the interval K2 in the region Y, and the width W2 of the groove <NUM> in the region Y is changed so as to be greater than the width W1 of the groove <NUM> in the region X.

More specifically, according to the first exemplary embodiment, the interval K1 between the grooves <NUM> in the region X is set to <NUM>, and the interval K2 between the grooves <NUM> in the region Y is set to <NUM>. In this case, the contact area between the blade 16a and the intermediate transfer belt <NUM> is <NUM>% in the region X and is <NUM>% in the region Y For this reason, according to the present exemplary embodiment, to satisfy a dynamic friction coefficient relationship the same as in the first exemplary embodiment, both the interval K1 and the interval K2 are set to <NUM>, the width W1 of the groove <NUM> in the region X is set to <NUM>, and the width W2 of the groove <NUM> in the region Y is set to <NUM>. In this manner, the effect the same as that of the first exemplary embodiment can be obtained.

Note that like the first exemplary embodiment, even in the present exemplary embodiment, the width W1 and the width W2 of the grooves <NUM> are preferably less than about half the average particle diameter of the toner, from a cleaning performance perspective. This is because if the width W1 and the width W2 of the grooves <NUM> are too large and if the toner enters the grooves <NUM>, the toner may slip through the blade nip portion Nb, resulting in faulty cleaning. However, if the width W1 and the width W2 of the grooves <NUM> are too small, the contact area between the blade 16a and the intermediate transfer belt <NUM> becomes too large, resulting in increased friction at the blade nip portion Nb and increased wear of the tip portion of the blade 16a. For this reason, even in the configuration of the present exemplary embodiment, the width W1 and the width W2 of the grooves <NUM> are preferably set to a value greater than or equal to <NUM> and less than or equal to <NUM>. In addition, like the first exemplary embodiment, according to the present exemplary embodiment, it is desirable that the difference between the dynamic friction coefficients in the region X and the region Y be less than or equal to <NUM>.

As described above, according to the configuration of the present exemplary embodiment, the same effects as those of the first exemplary embodiment can be obtained. Furthermore, the grooves <NUM> can be adjusted so that the change in the dynamic friction coefficient from the region X to the region Y or from the region Y to the region X is continuous. As a result, the tuck portion M can be continuously changed in the movement direction of the intermediate transfer belt <NUM>, and slipping-through of the residual transfer toner and turn-over of the blade 16a can be more effectively prevented when the posture of the blade 16a changes.

While the present exemplary embodiment has been described with reference to the configuration in which the interval K1 between the grooves <NUM> in the region X is the same as the interval K2 in the region Y and, moreover, the width W2 of the groove <NUM> in the region Y is changed so as to be greater than the width W1 of the groove <NUM> in the region X, the configuration is not limited thereto. Any interval K1 between the grooves <NUM> in the region X and any interval K2 in the region Y that differs from the interval K1 may be set if the difference between the dynamic friction coefficients in the region X and the region Y is less than or equal to <NUM> and the width W1 and the width W2 of the grooves <NUM> are greater than or equal to <NUM> or more and less than or equal to <NUM>. Other Exemplary Embodiments.

Another configuration of the image forming apparatus <NUM> according to the first exemplary embodiment is described below that further improves the durability of the blade 16a. The same reference numerals are used in the following description to describe those constituent elements that are identical to the constituent elements of the first exemplary embodiment, and description of the constituent elements are not repeated.

More specifically, according to the present exemplary embodiment, if image formation is not performed for a long period of time, the movement of the intermediate transfer belt <NUM> is stopped with the blade 16a in contact with the region Y of the intermediate transfer belt <NUM>. In this manner, the operation performed by the image forming apparatus <NUM> is stopped. In this case, the tuck amount m is small as compared with the case where the operation of the image forming apparatus <NUM> is stopped with the blade 16a in contact with the region X of the intermediate transfer belt <NUM>. Thus, a force exerted on the stress concentration portion Py of the blade 16a can be reduced. As a result, deformation of the edge portion of the blade 16a can be prevented more, and the durability of the blade 16a can be improved more.

It can be determined which one of the region X and the region Y of the intermediate transfer belt <NUM> the blade 16a is in contact with by, for example, providing a detection unit that detects the position of the intermediate transfer belt <NUM>. Alternatively, the positions of the region X and the region Y may be detected by detecting the positon of the intermediate transfer belt <NUM> with a detection unit, such as a sensor, that detects a detection toner image to be transferred from the photoconductive drum <NUM> to the intermediate transfer belt <NUM> in order to set the image formation conditions.

A third exemplary embodiment is described below with reference to <FIG>. An image forming apparatus <NUM> according to the present exemplary embodiment does not include a contact member that is in contact with the photoconductive drums 1a to 1d, each serving as an image bearing member, and that collects toner remaining on the photoconductive drums 1a to 1d (transfer residual toner. That is, the image forming apparatus <NUM> has a configuration known as a cleaner-less configuration. In such a cleaner-less configuration, if an adhering substance, such as transfer residual toner, on the photoconductive drums 1a to 1d cannot be sufficiently removed from the surfaces of the photoconductive drums 1a to 1d, image defect caused by the adhering substance may occur. According to the present exemplary embodiment, a cleaner-less configuration of an image forming apparatus capable of preventing the occurrence of image defect caused by an adhering substance on the photoconductive drums 1a to 1d is described.

<FIG> is a schematic cross-sectional view of the configuration of the image forming apparatus <NUM> according to the present exemplary embodiment. As illustrated in <FIG>, the image forming apparatus <NUM> according to the present exemplary embodiment is what is called a tandem type image forming apparatus provided with a plurality of image forming units a to d. The first image forming unit a forms an image by using yellow (Y) toner, the second image forming unit b forms an image by using magenta (M) toner, the third image forming unit c forms an image by using cyan (C) toner, and the fourth image forming unit d forms an image by using black (Bk) toner. These four image forming units are arranged in a line at regular intervals, and the four image forming units have substantially the same configuration except for the color of the toner to be stored. So, the image forming apparatus according to the present exemplary embodiment is described below with reference to the first image forming unit a.

The first image forming unit a includes a photoconductive drum 1a which is a drum-shaped photoconductive member, a charging roller 2a which is a charging member, an exposure unit 3a, and a developing unit 4a. The photoconductive drum 1a is an image bearing member that bears a toner image and is driven to rotate in a direction indicated by an arrow R1 in <FIG> (a counterclockwise direction) at a predetermined peripheral speed (process speed) in response to a driving force received from a driving source (not illustrated). Note that the image forming units a to d according to the present exemplary embodiment have a configuration known as a cleaner-less configuration in which cleaning members in contact with the photoconductive drums 1a to 1d are not provided.

When a control unit (not illustrated) receives an image signal, an image forming operation is started, and the photoconductive drum 1a is driven to rotate. During rotation, the photoconductive drum 1a is uniformly charged to a predetermined potential with a predetermined polarity (a negative polarity according to the present exemplary embodiment) by the charging roller 2a and is exposed to light in accordance with the image signal by the exposure unit 3a. In this way, an electrostatic latent image corresponding to the yellow component image of a target color image is formed. Subsequently, the electrostatic latent image is developed by the developing unit 4a at a development position and is visualized on the photoconductive drum 1a as a yellow toner image. According to the present exemplary embodiment, the normal charging polarity of the toner stored in the developing unit 4a is a negative polarity. An electrostatic latent image is developed using discharged area development, with the toner charged to the same polarity as the charging polarity of the photoconductive drum 1a by the charging roller 2a. However, the present invention is applicable to an image forming apparatus that develops an electrostatic latent image by using charged area development, with toner charged to a positive polarity which is opposite to the charging polarity of the photoconductive drum 1a.

The charging roller 2a serving as a charging member is in contact with a surface of the photoconductive drum 1a and is driven to rotate by the rotation of the photoconductive drum 1a due to friction with the surface of the photoconductive drum 1a. In addition, the charging roller 2a is a roller member in which a core metal having a diameter of <NUM> is provided with an elastic layer made from a conductive elastic body having a thickness of <NUM> and a volume resistivity of about <NUM> × <NUM><NUM> Ω·cm. The charging roller 2a receives a predetermined voltage from a charging power source (not illustrated) in accordance with an image forming operation. Note that when a voltage of -<NUM> (V) is applied to the charging roller 2a from the charging power source (not illustrated), the surface potential of the photoconductive drum 1a is about -<NUM> (V) (measured using Model <NUM> Electrostatic Voltmeter available from TREK, INC.

The exposure unit 3a includes a laser driver, a laser diode, a polygon mirror, an optical system lens, and the like. The exposure unit 3a emits a laser beam in accordance with image information input from a host computer (not illustrated) and forms an electrostatic latent image on the surface of the photoconductive drum 1a. According to the present exemplary embodiment, the amount of light is controlled such that when the photoconductive drum 1a is exposed to the maximum amount of light emitted from the exposure unit 3a, a surface potential Vl of the photoconductive drum 1a is -<NUM> (V).

The developing unit 4a includes a development roller 42a serving as a developing member and yellow toner. The developing unit 4a supplies the toner to the photoconductive drum 1a and develops an electrostatic latent image formed on the photoconductive drum 1a into a toner image. The development roller 42a can be brought into contact with the photoconductive drum 1a and can be separated from the photoconductive drum 1a. The development roller 42a is brought into contact with the photoconductive drum 1a (the contact width is predetermined) and supplies the toner. The development roller 42a rotates in a direction opposite to an arrow R1 illustrated in <FIG> (a clockwise direction) at a peripheral speed higher than the peripheral speed of the photoconductive drum 1a. A developing power source (not illustrated) is connected to the development roller 42a, and a predetermined voltage (-<NUM> (V) according to the present exemplary embodiment) is applied to the development roller 42a in accordance with an image forming operation.

According to the present exemplary embodiment, the toner is nonmagnetic one-component toner produced by a suspension polymerization process. The toner has a negative normal charging polarity. The volume average particle diameter of the toner measured with the laser diffraction particle size distribution analyzer LS-<NUM> available from Beckman Coulter, Inc. Furthermore, to modify the surface property, silicon oxide particles, with a weight of about <NUM>% of the toner, are made to adhere to the surfaces of the toner particles as an external additive. The volume average particle diameter of the silicon oxide particle is about <NUM>. According to the present exemplary embodiment, toner produced by a suspension polymerization process is employed. However, the toner is not limited thereto. For example, the toner produced by using another polymerization process, such as a pulverization process or an emulsion polymerization process, may be employed.

The intermediate transfer belt <NUM> serving as an intermediate transfer member is a movable endless belt having conductivity produced by adding a conductive agent to a resin material. The intermediate transfer belt <NUM> is stretched around three axes of stretching rollers <NUM>, <NUM>, and <NUM>. The photoconductive drums 1a to 1d are driven to rotate at substantially the same peripheral speed. The intermediate transfer belt <NUM> is in contact with the photoconductive drum 1a to form a primary transfer portion N1a, and the yellow toner image formed on the photoconductive drum 1a is primarily transferred from the photoconductive drum 1a in the process of passing through the primary transfer portion N1a.

A primary transfer roller 14a serving as a transfer member is provided adjacent to the inner peripheral surface of the intermediate transfer belt <NUM> so as to face the photoconductive drum 1a with the intermediate transfer belt <NUM> therebetween. A primary transfer power source <NUM> serving as a potential forming unit is connected to the primary transfer roller 14a. The primary transfer roller 14a is formed as a straight nickel-plated SUS round bar having an outer diameter of <NUM>. The primary transfer roller 14a is in contact with the intermediate transfer belt <NUM> over a predetermined region of the intermediate transfer belt <NUM> in the longitudinal direction crossing the movement direction of the intermediate transfer belt <NUM>. The intermediate transfer belt <NUM> is driven to rotate by the revolution of the intermediate transfer belt <NUM>.

In accordance with the image forming operation, the primary transfer power source <NUM> applies a voltage of <NUM> (V) to the primary transfer roller 14a. As a result, a potential is formed on the conductive intermediate transfer belt <NUM>, and the yellow toner image is primarily transferred from the photoconductive drum 1a to the intermediate transfer belt <NUM>. Note that according to the present exemplary embodiment, a configuration in which a voltage is applied from the primary transfer power source <NUM> common to the primary transfer rollers 14a to 14d is employed. However, the present invention is not limited thereto, and transfer power sources for applying voltages to the primary transfer rollers 14a to 14d may be provided individually. Alternatively, only some of the primary transfer rollers 14a to 14d may use a common transfer power source.

Similarly, the second, third, and fourth image forming units b, c, and d form a second color magenta toner image, a third color cyan toner image, and a fourth color black toner image, respectively. The toner images are sequentially primarily transferred to the intermediate transfer belt <NUM> on top of another. As a result, four color toner images corresponding to the target color image are formed on the intermediate transfer belt <NUM>. Subsequently, when the four color toner images born by the intermediate transfer belt <NUM> pass through a secondary transfer portion N2 formed by contact of a secondary transfer roller <NUM> with the intermediate transfer belt <NUM>, the four color toner images are secondarily transferred onto a surface of a transfer medium P, such as a paper sheet or an OHP sheet, fed by a sheet feeding unit <NUM> in one go.

A secondary transfer roller <NUM> serving as a secondary transfer member has an outer diameter of <NUM>. The secondary transfer roller <NUM> is formed by covering a nickel-plated steel rod having an outer diameter of <NUM> with a foamed sponge body mainly composed of NBR and epichlorohydrin rubber and having an adjusted volume resistivity of <NUM><NUM> Ω·cm and an adjusted thickness of <NUM>. Note that the rubber hardness of the foamed sponge body was measured by using Asker hardness meter type C, and the hardness was <NUM>°. The secondary transfer roller <NUM> is in contact with the outer circumferential surface of the intermediate transfer belt <NUM>. The secondary transfer roller <NUM> applies a pressure of about <NUM> N to the facing roller <NUM> serving as a facing member via the intermediate transfer belt <NUM> and forms a secondary transfer portion N2. A secondary transfer power source <NUM> is connected to the secondary transfer roller <NUM>. When the secondary transfer power source <NUM> applies a voltage to the secondary transfer roller <NUM>, the toner image is secondarily transferred from the intermediate transfer belt <NUM> to a transfer medium P in the secondary transfer portion N2. Note that the secondary transfer power source <NUM> can output a voltage in the range of <NUM> to <NUM> (V). According to the present exemplary embodiment, the secondary transfer power source <NUM> applies a voltage of <NUM> (V). Thus, the toner image is secondarily transferred from the intermediate transfer belt <NUM> to the transfer medium P in the secondary transfer portion N2.

Subsequently, the four color toner images born by the intermediate transfer belt <NUM> are transferred onto the transfer medium P in the secondary transfer portion N2. Thereafter, the transfer medium P is led to a fixing unit <NUM>, where the transfer medium P is heated and pressurized. Thus, the four color toner particles are melted and mixed and are fixed to the transfer medium P. The toner remaining on the intermediate transfer belt <NUM> after the secondary transfer is cleaned or removed by a cleaning unit <NUM>. The cleaning unit <NUM> is provided so as to face the facing roller <NUM> via the intermediate transfer belt <NUM> and serves as a collection unit that collects toner remaining on the intermediate transfer belt <NUM>. The cleaning unit <NUM> includes a cleaning blade 17a that is in contact with the outer circumferential surface of the intermediate transfer belt <NUM> and a waste toner container 17b that stores toner removed from the intermediate transfer belt <NUM> by the cleaning blade 17a and the like.

According to the present exemplary embodiment, the image forming apparatus <NUM> does not include a contact member that is in contact with the photoconductive drum 1a and collects the residual transfer toner before the toner that has passed through the primary transfer portion N1a and remains on the photoconductive drum 1a reaches a charging unit in which the charging roller 2a is in contact with the photoconductive drum 1a. More specifically, the image forming apparatus <NUM> has what is called cleaner-less configuration that does not include a collection member, such as a cleaning blade, that is in contact with the photoconductive drum 1a between the primary transfer portion N1a and the charging unit in the rotational direction of the photoconductive drum 1a. Accordingly, the transfer residual toner that remains on the photoconductive drum 1a after the primary transfer of the toner image from the photoconductive drum 1a to the intermediate transfer belt <NUM> is collected by the developing unit 4a after passing through the charging unit.

According to the image forming apparatus of the present exemplary embodiment, a full-color print image is formed through the above-described operation. Intermediate Transfer Belt.

The intermediate transfer belt <NUM> that is a feature of the present exemplary embodiment is described below. The intermediate transfer belt <NUM> is a cylindrical endless belt. The intermediate transfer belt <NUM> has a circumference of <NUM>. The intermediate transfer belt <NUM> has two layers, a base layer and a surface layer. The material of the base layer is polyimide resin, and the material of the surface layer is acrylic resin. The base layer is <NUM> in thickness, and the surface layer is <NUM> in thickness. As used herein, the term "surface layer of the intermediate transfer belt <NUM>" refers to a layer that forms the outer circumferential surface of the intermediate transfer belt <NUM>, that is, a layer in contact with the cleaning blade 17a and the photoconductive drums 1a to 1d. In contrast, the term "base layer of the intermediate transfer belt <NUM>" refers to the thickest one of a plurality of layers that constitute the intermediate transfer belt <NUM> with respect to the thickness direction of the intermediate transfer belt <NUM>.

<FIG> is a schematic illustration of a groove 310a formed on the surface layer of the intermediate transfer belt <NUM> according to the present exemplary embodiment and is a schematic developed illustration of the endless intermediate transfer belt <NUM>. As illustrated in <FIG>, a surface (the surface layer) of the intermediate transfer belt <NUM> according to the present exemplary embodiment has a plurality of grooves 310a each formed at an angle of θ to an imaginary line VL extending in the movement direction of the intermediate transfer belt <NUM>. According to the present exemplary embodiment, θ = <NUM>°, and the grooves 310a are formed at intervals of I (I = <NUM>) in the width direction crossing the movement direction of the intermediate transfer belt <NUM>. Note that according to the present exemplary embodiment, the interval I between adjacent grooves is set to satisfy the following expression (<NUM>) using the circumferential length L of the intermediate transfer belt <NUM> and the angle θ: <MAT>.

<FIG> is a schematic enlarged cross-sectional view of a contact portion between the photoconductive drum 1a and the intermediate transfer belt <NUM> in the primary transfer portion N1a, as viewed in the movement direction of the intermediate transfer belt <NUM>. As illustrated in <FIG>, according to the present exemplary embodiment, the grooves 310a each having a width of <NUM> and a depth of <NUM> are formed on the surface of the intermediate transfer belt <NUM>. Note that the width and depth of the groove <NUM>10a are not limited to the values described above to obtain the effects of the present exemplary embodiment. However, it is more desirable that the values be less than or equal to the average particle diameter of the toner in consideration of the primary transferability of the toner.

The image forming apparatus <NUM> according to the present exemplary embodiment has a cleaner-less configuration that does not include cleaning units each in contact with the photoconductive drums 1a to 1d and collect residual transfer toner. For this reason, if residual transfer toner is not sufficiently collected by the developing units 4a to 4d, that is, if some of the residual transfer toner particles, external additives, and the like adhere to the surfaces of the photoconductive drums 1a to 1d as an adhering substance, the adhering substance may appear on the transfer medium P as an image defect. In the following description, when the same control and operation are performed for each of the member of the image forming units a to d, the suffixes "a" to "b" each attached to a reference number and indicating which one of the image forming units includes the member are removed.

<FIG> is a schematic enlarged cross-sectional view of the point at which the intermediate transfer belt <NUM> and the photoconductive drum <NUM> are in contact with each other according to the present exemplary embodiment. As illustrated in <FIG>, according to the present exemplary embodiment, the grooves 310a are formed on the surface of the intermediate transfer belt <NUM> so that a adhering substance W on the photoconductive drum <NUM> is easily scraped off from the photoconductive drum <NUM>. More specifically, as the intermediate transfer belt <NUM> moves, an edge portion of the groove 310a moves while being in contact with the surface of the photoconductive drum <NUM>. In this way, the adhering substance W can be scraped off from the photoconductive drum <NUM>.

Furthermore, as illustrated in <FIG>, according to the present exemplary embodiment, an angle θ is formed between the groove 310a and the movement direction of the intermediate transfer belt <NUM>, and the interval I between the adjacent grooves 310a in the width direction of the intermediate transfer belt <NUM> is set to be less than or equal to the circumferential length L of the intermediate transfer belt <NUM> × tanθ. Thus, while the intermediate transfer belt <NUM> and the photoconductive drum <NUM> are rotating, the grooves 310a pass through all the points of the photoconductive drum <NUM> in the width direction of the intermediate transfer belt <NUM>, that is, in the longitudinal direction of the photoconductive drum <NUM>. As a result, according to the configuration of the present exemplary embodiment, the adhering substance W on the surface of the photoconductive drum <NUM> can be scraped off by the grooves 310a.

The effect of the present exemplary embodiment is described in detail below with reference to Comparative Example <NUM>. In Comparative Example <NUM>, an intermediate transfer belt having no groove-like concave portions was used. Comparative Example <NUM> is substantially the same as the present exemplary embodiment except that no groove is formed on the surface of the intermediate transfer belt. For this reason, the same reference numerals are used in Comparative example <NUM> to describe those constituent elements that are identical to the constituent elements of the present exemplary embodiment, and description of the constituent elements are not repeated. Image Evaluation.

To evaluate whether image defect occurred, an image having a printing ratio of <NUM>% was continuously printed on <NUM> transfer media P (A4 size paper sheets with a basis weight of <NUM>/m2, Red Label available from Oce). Thereafter, to determine whether image defect occurred, a test images was formed. The test image was a toner image having a printing ratio of <NUM>% (a solid black image) formed in an area of the transfer medium P defined by the range of <NUM> to <NUM> from the leading edge of the transfer medium P in the conveyance direction and the entire image forming area in the width direction. Such a test image was formed on the transfer medium P. Thereafter, image evaluation was carried out by determining whether the image defect occurred in an area having no toner image (a solid white portion) upstream of the area having the solid black image formed therein (a solid black portion) in the conveyance direction of the transfer medium P.

As a result of the above-described image evaluation, no image defect is observed for the configuration according to the present exemplary embodiment. In contrast, according to the configuration of Comparative Example <NUM>, image defect occurs in which the toner for the solid black portion adheres to the solid white portion (hereinafter, the image defect is referred to as "transfer residual ghost"). More specifically, the transfer residual ghost is an image defect that occurs when the photoconductive drum <NUM> makes one rotation with the residual transfer toner thereon and, thereafter, the transfer residual toner is transferred to the intermediate transfer belt <NUM> in the next primary transfer process.

According to the configuration of the present exemplary embodiment, the grooves 310a are provided in the intermediate transfer belt <NUM>. Thus, it is possible to scrape off toner or external additives attached to the photoconductive drum <NUM> by the intermediate transfer belt <NUM> that is moving. As a result, it is possible to prevent toner, external additives, and the like from adhering to the photoconductive drum <NUM> as the adhering substance W and to prevent the occurrence of an image defect, such as a transfer residual ghost.

In contrast, according to the configuration of Comparative Example <NUM>, since no groove is formed in the intermediate transfer belt, an adhering substance W, such as some of the transfer residual toner and external additives, adhere to the surface of the photoconductive drum <NUM>. As a result, a transfer residual ghost is generated due to an increase in transfer residual toner. This is because when the adhering substance W, such as transfer residual toner and external additives, adheres to the photoconductive drum <NUM>, the releasability of the toner from the photoconductive drum <NUM> is reduced, so that the amount of the residual transfer toner that remains on the photoconductive drum <NUM> after the primary transfer process increases. For this reason, a transfer residual ghost easily occurs.

As described above, according to the configuration of the present exemplary embodiment, the grooves 310a that are at an angle θ to the movement direction of the intermediate transfer belt <NUM> are formed on the surface of the intermediate transfer belt <NUM>. In addition, the interval I between the grooves 310a is set to be less than or equal to the circumferential length L of the intermediate transfer belt <NUM> × tanθ. In this way, the adhering substance W on the photoconductive drum <NUM> can be removed from the surface of the photoconductive drum <NUM>, and the occurrence of image defects due to the adhering substance W can be reduced.

According to the present exemplary embodiment, the intermediate transfer belt <NUM> composed of two layers, the base layer and the surface layer, has been described. However, the layer structure of the intermediate transfer belt <NUM> is not limited thereto if the grooves <NUM> lOa are formed on the surface in contact with the photoconductive drum <NUM>. For example, the intermediate transfer belt <NUM> may be a single layer belt having only a base layer or a multilayer belt composed of three or more layers.

According to the third exemplary embodiment, the configuration has been described in which the grooves <NUM> lOa that are at an angle θ to the movement direction of the intermediate transfer belt <NUM> are formed on the surface of the intermediate transfer belt <NUM>. In contrast, according to the fourth exemplary embodiment, a description is given of a configuration in which streaky convex portions 110b that are an angle θ to the movement direction of the intermediate transfer belt <NUM> (intermediate transfer member) are formed on the surface of the intermediate transfer belt <NUM>. Note that the configuration of the fourth exemplary embodiment is substantially the same as that of the third exemplary embodiment except that the intermediate transfer belt <NUM> provided with the streaky convex portions 110b is employed. Accordingly, in the following description, the same reference numerals are used for the configurations and control processes that are the same as those illustrated in the third exemplary embodiment, and descriptions of the configurations and control processes are not repeated.

<FIG> is a schematic illustration of the convex portions 110b formed on the surface layer of the intermediate transfer belt <NUM> according to the present exemplary embodiment and is a schematic developed illustration of the endless intermediate transfer belt <NUM>. As illustrated in <FIG>, a surface of the intermediate transfer belt <NUM> according to the present exemplary embodiment has a plurality of convex portions 110b formed thereon. The convex portions 110b are at an angle θ to an imaginary line VL extending in the movement direction of the intermediate transfer belt <NUM>. According to the present exemplary embodiment, θ = <NUM>°, and the convex portions 110b are formed at intervals I of <NUM> in the width direction crossing the movement direction of the intermediate transfer belt <NUM>. Note that according to the present exemplary embodiment, the interval I between the adjacent convex portions is set so as to satisfy Expression (<NUM>) of the third exemplary embodiment.

<FIG> is a schematic enlarged cross-sectional view of a contact portion between the photoconductive drum 1a and the intermediate transfer belt <NUM> in the primary transfer portion N1a, as viewed in the movement direction of the intermediate transfer belt <NUM>. As illustrated in <FIG>, according to the present exemplary embodiment, the convex portions 110b each having a width of <NUM> and a height of <NUM> are formed on the surface of the intermediate transfer belt <NUM>. Note that the width and height of the convex portion 110b are not limited to the values described above to obtain the effects of the present exemplary embodiment. However, it is desirable that the width and height of the convex portion 110b be set to be less than or equal to the average particle diameter of the toner in consideration of the primary transferability of the toner.

n addition to the transfer residual toner and the external additives described in the third exemplary embodiment, a corona product, such as nitride oxide, may adhere to the surface of the photoconductive drum <NUM>. Such a corona product is generated by discharge generated in the vicinity of the charging unit where the charging roller 2a and the photoconductive drum 1a are in contact with each other. The corona product gradually accumulates on the photoconductive drum <NUM> as the image forming operation is repeated. If the amount of the corona product accumulated on the photoconductive drum <NUM> increases, the corona product absorbs moisture in a high-humidity environment, which reduces the resistance thereof and disturbs the charge in the latent image formed on the photoconductive drum <NUM>. As a result, an image defect that reduces the density of an image may occur.

To solve such a problem, as illustrated in <FIG>, the present exemplary embodiment employs a configuration capable of easily scraping off the adhering substance W, such as a corona product, on the photoconductive drum <NUM> by forming the convex portions 110b on the surface of the intermediate transfer belt <NUM>. More specifically, as the intermediate transfer belt <NUM> moves, the convex portions 110b move while being in contact with the surface of the photoconductive drum <NUM>. In this manner, the adhering substance W can be scraped off from the photoconductive drum <NUM>.

Furthermore, as illustrated in <FIG>, according to the present exemplary embodiment, an angle θ is formed by each of the convex portions 110b and the movement direction of the intermediate transfer belt <NUM>. In addition, the interval I between the convex portions 110b in the width direction of the intermediate transfer belt <NUM> is set to be less than or equal to the circumferential length L of the intermediate transfer belt <NUM> × tanθ. In this way, after many revolutions of the intermediate transfer belt <NUM> and the photoconductive drum <NUM>, the convex portion 110b passes through all points of the photoconductive drum <NUM> in the width direction of the intermediate transfer belt <NUM>, that is, all points of the photoconductive drum <NUM> in the longitudinal direction of the photoconductive drum <NUM>. As a result, according to the configuration of the present exemplary embodiment, the adhering substance W on the surface of the photoconductive drum <NUM> can be scraped off by the convex portions 110b.

The effect of the present exemplary embodiment is described in detail below by comparing the effect with the effect of Comparative Example <NUM>. In Comparative Example <NUM>, an intermediate transfer belt having no convex portion formed thereon was used. Note that the other configurations of Comparative Example <NUM> are substantially the same as those of the present exemplary embodiment except that no convex portion is formed on the surface of the intermediate transfer belt. Accordingly, in the following description, the same reference numerals are used for the constituent elements that are the same as those in Comparative Example <NUM>, and descriptions of the constituent elements are not repeated.

To determine whether image defect occurred, two types of test images were formed by using transfer media P (A4 size paper sheets with a basis weight of <NUM>/m2, Red Label available from Oce). Thereafter, the occurrence of the image defect was examined for the two types of test images. In first image evaluation, like the image evaluation carried out in the third exemplary embodiment, an image having a printing ratio of <NUM>% was continuously printed on <NUM> transfer media P. Subsequently, to determine whether a transfer residual ghost occurred, the test images were formed. As described above, the test image was a toner image having a printing ratio of <NUM>% (a solid black image) formed in an area of the transfer medium P defined by the range of <NUM> to <NUM> from the leading edge of the transfer medium P in the conveyance direction and the entire image forming area in the width direction.

In second image evaluation, the image forming apparatus <NUM> were placed in a high-temperature and high-humidity environment (a temperature of <NUM> and a humidity of <NUM>%) for three days. Thereafter, images having a printing ratio of <NUM>% were continuously printed on <NUM> transfer media P. Subsequently, test images were formed to determine whether an image defect occurred. Note that the test image is a halftone image formed in the entire image forming area of the transfer medium P and having a printing ratio of <NUM>%. Such test images were formed on the transfer media P, and it was determined whether an image defect that reduced the density of an image due to the corona product occurred.

As a result of the above-described image evaluation, according to the configuration of the present exemplary embodiment, neither a transfer residual ghost nor an image defect that reduces the density of an image occurs. In contrast, according to the configuration of Comparative Example <NUM>, both a transfer residual ghost and an image defect that reduces the density of a halftone image having a printing ratio of <NUM>% are found out.

As described above, according to the configuration of the present exemplary embodiment, the convex portions 110b are provided on the intermediate transfer belt <NUM>, so that the toner and external additives adhering to the photoconductive drum <NUM> in accordance with the movement of the intermediate transfer belt <NUM> and a corona product can be scraped off. In this manner, it is possible to prevent accumulation of toner, external additives, corona products, and the like as adhering substances W on the photoconductive drum <NUM>. Thus, the occurrence of a residual transfer ghost and an image defect that reduces the density of an image can be reduced.

In contrast, according to the configuration of Comparative Example <NUM>, since the convex portions are not formed on the intermediate transfer belt, the adhering substance W, such as some of the transfer residual toner, external additives, or corona products, are easily accumulated on the surface of the photoconductive drum <NUM>. As a result, a transfer residual ghost or an image defect that reduces the density of an image occurs. If the adhering substance W, such as the residual transfer toner and the external additives, is accumulated on the photoconductive drum <NUM>, the releasability of the toner on the photoconductive drum <NUM> is reduced, so that the amount of transfer residual toner remaining on the photoconductive drum <NUM> after the primary transfer increases. For this reason, a transfer residual ghost easily occurs. Furthermore, if an adhering substance W, such as a corona product, accumulates on the photoconductive drum <NUM>, the corona product adsorbs moisture, reduces the resistance, and disrupts the electric charge of a latent image formed on the photoconductive drum <NUM>. As a result, an image defect that reduces the density of a halftone image easily occurs.

As described above, according to the configuration of the present exemplary embodiment, the convex portions 110b that are at an angle θ to the movement direction of the intermediate transfer belt <NUM> are formed on the surface of the intermediate transfer belt <NUM>. In addition, the interval I between the convex portions 110b is set to be less than or equal to the circumferential length L of the intermediate transfer belt <NUM> × tanθ. In this way, the adhering substance W on the photoconductive drum <NUM> can be removed from the surface of the photoconductive drum <NUM> and, thus, the occurrence of image defects caused by the adhering substance W can be reduced.

The third exemplary embodiment has been described with reference to the configuration having the grooves 310a formed on the surface of the intermediate transfer belt <NUM> at an angle θ to the movement direction of the intermediate transfer belt <NUM>. In contrast, the fifth exemplary embodiment is described below with reference to a configuration having grooves 210a formed on the surface of the intermediate transfer belt <NUM> at an angle θ to the movement direction of the intermediate transfer belt <NUM> (intermediate transfer member) and streaky convex portions 210b formed on either side of each of the grooves 210a. Note that the configuration according to the fifth exemplary embodiment is substantially the same as that of the third exemplary embodiment except that an intermediate transfer belt <NUM> having the streaky convex portions 210b formed on either side of each of the grooves 210a is used. Accordingly, in the following description, the same reference numerals are used for the constituent elements that are the same as those of the third exemplary embodiment, and descriptions of the constituent elements are not repeated.

Like the intermediate transfer belt <NUM> described in the third exemplary embodiment with reference to <FIG>, according to the present exemplary embodiment, a surface of the intermediate transfer belt <NUM> has the plurality of grooves 210a formed thereon at an angle θ to an imaginary line VL extending in the movement direction of the intermediate transfer belt <NUM>. According to the present exemplary embodiment, θ = <NUM>°. In addition, the grooves 210a are formed at intervals I of <NUM> in the width direction crossing the movement direction of the intermediate transfer belt <NUM>. Note that according to the present exemplary embodiment, the interval I between adjacent grooves is set so as to satisfy Expression (<NUM>) of the third exemplary embodiment.

<FIG> is a schematic enlarged cross-sectional view of a contact portion between the photoconductive drum 1a and the intermediate transfer belt <NUM> in the primary transfer portion N1a, as viewed in the movement direction of the intermediate transfer belt <NUM>. As illustrated in <FIG>, according to the present exemplary embodiment, the grooves 210a each having a width of <NUM> and a depth of <NUM> are formed on the surface of the intermediate transfer belt <NUM>. Furthermore, according to the present exemplary embodiment, the convex portions 210b are formed on either side of each of the groove 210a in the width direction of the intermediate transfer belt <NUM>. According to the present exemplary embodiment, the width and depth of the groove 210a are not limited to the values described above to obtain the effects of the present exemplary embodiment. However, it is desirable that each of the values be set to be less than or equal to the average particle diameter of the toner, in consideration of the primary transferability of the toner. More specifically, it is desirable that the sum of the depth of the groove 210a and the height of the convex portion 210b formed on both sides of the groove 210a be set to be less than or equal to the average particle diameter of the toner. Similarly, it is desirable that the sum of the width of the groove 210a and the width of the convex portion 210b formed on both sides of the groove 210a be set to be less than or equal to the average particle diameter of the toner.

To determine whether image defect occurred, two types of test images were formed by using transfer media P (A4 size paper sheet with a basis weight of <NUM>/m2, Red Label available from Oce). Thereafter, it was determined whether an image defect occurred for the two types of test images. In first image evaluation, like the image evaluation carried out in the third exemplary embodiment, an image having a printing ratio of <NUM>% was continuously printed on <NUM> transfer media P. Subsequently, to determine whether a transfer residual ghost occurred, a test image was formed. As described above, the test image was a toner image having a printing ratio of <NUM>% (a solid black image) formed in an area of the transfer medium P defined by the range of <NUM> to <NUM> from the leading edge of the transfer medium P in the conveyance direction and the entire image forming area in the width direction.

In a second image evaluation, the image forming apparatus <NUM> were placed in a high-temperature and high-humidity environment (a temperature of <NUM> and a humidity of <NUM>%) for three days. Thereafter, an image having a printing ratio of <NUM>% was continuously printed on <NUM> transfer media P. Subsequently, a test image was formed to determine whether an image defect occurred. Note that the test image was a halftone image formed in the entire image forming area of the transfer medium P and having a printing ratio of <NUM>%. Such a test image was formed on the transfer media P, and it was determined whether an image defect that reduced the density of an image due to the corona product occurred.

Furthermore, according to the present exemplary embodiment, the dynamic friction coefficient of the surface of the intermediate transfer belt <NUM> was measured before and after the second image evaluation, and a change in the dynamic friction coefficient of the intermediate transfer belt <NUM> before and after the image evaluation was checked. In the measurement, the dynamic friction coefficient was measured using a surface property tester ("HEIDON 14FW" available from Shinto Scientific Co. At this time, an urethane rubber ball indenter (with an outer diameter of <NUM>/<NUM> inch and a rubber hardness of <NUM> degrees) was used as a measurement indenter. The measurement conditions included a test load of <NUM> gf, a speed of <NUM>/sec, and a measurement distance of <NUM>. The values of the dynamic friction coefficient were obtained by dividing the average of the frictional forces (gf) measured in <NUM> second to <NUM> seconds from the start of measurement by the test load (gf).

As a result of the above-described image evaluation, like the third and fourth exemplary embodiments, in even the configuration according to the present exemplary embodiment, neither a transfer residual ghost nor an image defect that reduces the density of an image occurs. As described above, according to the configuration of the present exemplary embodiment, the convex portions 210b are provided on the intermediate transfer belt <NUM>. Consequently, toner, external additives, and a corona product adhering to the photoconductive drum <NUM> can be scraped off by the intermediate transfer belt <NUM> that is moving. As a result, it is possible to prevent accumulation of toner, external additives, corona products, and the like as adhering substances W on the photoconductive drum <NUM>. Thus, the occurrence of a residual transfer ghost and an image defect that reduces the density of an image can be reduced.

In addition, according to the configuration of the present exemplary embodiment, the dynamic friction coefficient of the intermediate transfer belt <NUM> before the second image evaluation is <NUM>, and the dynamic friction coefficient of the intermediate transfer belt <NUM> after the second image evaluation is <NUM>. That is, the dynamic friction coefficient is almost unchanged. This is because the groove 210a is formed in the vicinity of the convex portion 210b of the intermediate transfer belt <NUM> and, therefore, the adhering substance W, such as a corona product, scraped off from the photoconductive drum <NUM> by the intermediate transfer belt <NUM> is collected into the groove 210a. That is, the reason why a change in the dynamic friction coefficient is small is that a corona product and other adhering substance W scraped off from the photoconductive drum <NUM> are difficult to adhere to the surface of the intermediate transfer belt <NUM>.

If the friction coefficient of the intermediate transfer belt <NUM> changes greatly, contact between the cleaning blade 17a that collects toner remaining on the intermediate transfer belt <NUM> and the intermediate transfer belt <NUM> may become unstable. In this case, faulty cleaning may occur, or noise may be generated due to vibration of the cleaning blade 17a. For this reason, if as in the present exemplary embodiment, the dynamic friction coefficient of the intermediate transfer belt <NUM> is small, stable cleaning performance that lasts for a long time can be easily achieved.

In the third to fifth exemplary embodiments described above, the cleaner-less configurations of the image forming apparatus have been described that solve the problem of the occurrence of an image defect caused by an adhering substance on the photoconductive drums 1a to 1d. To solve the problems presented in the third to fifth exemplary embodiments, the intermediate transfer belt <NUM> does not necessarily have to have the region X and the region Y having different dynamic friction coefficients described in the first and second exemplary embodiments. However, it will be obvious that the configuration of the intermediate transfer belt having the region X and the region Y having different dynamic friction coefficients described in the first and second exemplary embodiments can be applied to the configuration of the intermediate transfer belts described in the third to fifth exemplary embodiments. According to the configuration of the image forming apparatus obtained in this way, the wear of the cleaning blade serving as a contact member can be reduced and, thus, the durability of the cleaning blade can be improved. At the same time, the occurrence of faulty cleaning can be prevented. Furthermore, an image defect caused by an adhering substance on the photoconductive drum can be reduced.

Claim 1:
An image forming apparatus comprising:
a photoconductive member (1a,1b 1c,1d) configured to bear a toner image;
a movable endless intermediate transfer member (<NUM>, <NUM>, <NUM>) in contact with the photoconductive member, the toner image born by the photoconductive member being primarily transferred to the intermediate transfer member (<NUM>, <NUM>, <NUM>); and
a developing unit (4a, 4b, 4c, 4d) configured to develop the toner image on the photoconductive member, the developing unit capable of collecting residual toner remaining on the photoconductive member after the toner image is primarily transferred from the photoconductive member to the intermediate transfer member (<NUM>, <NUM>, <NUM>),
wherein the intermediate transfer member (<NUM>, <NUM>, <NUM>) has a plurality of grooves (210a, 310a) formed on a surface in contact with the photoconductive member, and the grooves continuously extend in a movement direction of the intermediate transfer member (<NUM>, <NUM>, <NUM>) and are arranged in a width direction crossing the movement direction of the intermediate transfer member (<NUM>, <NUM>, <NUM>), and
wherein the grooves are diagonally formed at an angle θ to the movement direction and satisfies the following Expression (<NUM>): <MAT> where I represents an interval between adjacent ones of the grooves in the width direction, and L represents a circumferential length of the intermediate transfer member (<NUM>, <NUM>, <NUM>) in the movement direction, characterized in that the intermediate transfer member (<NUM>, <NUM>) has convex portions (110b) formed on either side of one of the grooves in the width direction, and the convex portions (110b) continuously extend in the movement direction of the intermediate transfer member (<NUM>, <NUM>).