Patent Application
20090142103
The present application is directed to cartridges for use with image forming devices and, more particularly, to a cartridge with one or more engaging features that engage with the image forming device during insertion.
Toner cartridges contain a predetermined amount of toner. The cartridges are constructed to be inserted into and engage with the image forming device. This engagement provides for the toner in the cartridge to be transferred into the image forming device and ultimately to a media sheet during the image formation process. The engagement between the cartridge and image forming device is important to ensure the cartridge operates properly within the image forming device to transfer the toner.
The cartridge should be constructed to prevent toner leakage prior to insertion into the device, and after insertion into the device. The cartridge may include a closure mechanism that prevents the toner from escaping prior to insertion into the image forming device. During insertion, the cartridge should engage with the image forming device in a manner to move the closure mechanism from a closed position to an open position that allows the toner to move from the cartridge and into the image forming device.
The cartridge should be carefully aligned relative to the image forming device to ensure accurate insertion that prevents toner leakage. The cartridge may include one or more engagement features that engage with the image forming device that provide accurate alignment. The engagement features may be positioned at various locations on the body of the cartridge.
The present application is directed to toner cartridges for use with image forming devices. The cartridge may include an interior to contain toner that is transferred to the image forming device and used during image formation. The cartridge may include one or more engagement features that interact with the image forming device during insertion. The engagement features may include one or more alignment features that align the cartridge during insertion into the image forming device. The engagement features may also include one or more functional features for the cartridge to effectively transfer the toner to the image forming device.
The present application is directed to toner cartridges for use within image forming devices.
Cartridge 10 includes a main section 38 and an extension 17. The extension 17 is positioned at the bottom 13 of the cartridge 10. As illustrated in
One or more of the engagement features 11 align the cartridge 10 during insertion into the image forming device 10. Many of these are located on the extension 17 because the extension 17 is initially inserted into the device 10 during a vertical insertion of the cartridge 10. One engagement features 11 includes chamfers 18 that are positioned on the bottom 13. Chamfers 18 may be positioned on a single side or multiple sides of the extension. In one embodiment, the extension includes a substantially rectangular cross-sectional shape and chamfers 18 are positioned along each of the four edges.
Another engagement feature 11 for alignment includes one or more ribs 19 that extend in a substantially vertical orientation along the extension 17. In one embodiment, the ribs 19 include a leading end 27 that faces towards the bottom 13. In one embodiment, the leading end 27 is spaced away from the chamfer 18 and makes contact with the device 100 after contact is made by the chamfer 18. The leading end 27 may include a chamfer, or may extend substantially perpendicularly outward from the extension 17. The length may vary, with the embodiment illustrated including the ribs 19 extending along the length of the extension 17. In this embodiment, ribs 19 are positioned on each of the sides 16, although other embodiments may include positioning at other locations. In embodiments with multiple ribs 19, the ribs 19 may include the same or different shapes and sizes. In one embodiment, the cartridge 10 includes a single rib 19.
Another alignment engagement feature 11 includes one or more slots 28. Slots 28 may be positioned at a variety of locations along the cartridge 10, including facing towards the side 16 as illustrated in
Another alignment engagement feature 11 includes a lockout mechanism 33 to control the location of insertion of the cartridge 10 into the image forming device 100. The lockout mechanism 33 prevents a specific cartridge 10 from being inserted into an incorrect receiving area 101. By way of example, the lockout mechanism 33 may prevent a black toner cartridge 10 from being inserted into a receiving area 101 for a cyan, yellow or magenta cartridge 10. The lockout mechanism 33 may include a pointed first end 34 that faces towards the bottom 13. The pointed first end 34 is positioned above the chamfer 18. In one embodiment, the lockout mechanism 33 is positioned on the front face 14 of the extension 17. One embodiment of a lockout mechanism is disclosed in U.S. patent Ser. No. 11/388,848 herein incorporated by reference.
The engagement features 11 may also include functional features that cause the cartridge 10 to operate within the image forming device 100 and move the toner to the image forming device 100. One functional engagement feature 11 includes an outlet 50 and shutter 51. Outlet 50 is positioned to allow the toner to be moved from the interior 33 of the cartridge 10. As illustrated in
Another functional engagement feature 11 is a drive gear 60 positioned on the front 14 of the cartridge 10. The drive gear 60 meshes with and receives rotational power from a corresponding gear in the image forming device 100. In the embodiment illustrated in
The outlet 50 with the shutter 51 and the drive gear 60 are each positioned on the main section 38 of the cartridge 10. The outlet 50 is positioned below a center of the drive gear 60.
The drive gear 60 transfers power from the image forming device 100 to various elements on the cartridge 10. One element includes an auger 70 as illustrated in
One or more paddles 75 may also be positioned within the interior 33 to agitate the toner. Each of the paddles 75 includes a central shaft 76 that extends through the interior 33, and a blade (not illustrated) that extends outward from the central shafts 76. Rotation of the central shafts 76 causes the blades to rotate to prevent toner from becoming compressed together, and also move the toner towards the auger 70. In one embodiment, a wall is positioned within the interior 33 between the auger 70 and the paddles. Toner is moved from a first side of the wall by the paddles into a second side of the wall that includes the auger 70. The wall prevents the toner from moving away from the auger 70 to a lower section of the interior 33.
A shaft 61 extends through the interior 33 and is operatively connected to the drive gear 60. The shaft 61 extends through the interior and is operatively connected to a gear 78 as illustrated in
Another functional engagement feature 11 on the cartridge 10 includes an electrical connector 80 as illustrated in
Housing 82 is constructed to position the circuit board 81 for engaging with a connector 150 within the image forming device 100. Housing 82 includes a base 85 with one or more outwardly-extending arms 86. Base 85 includes an opening 87 sized to receive the circuit board 81. A member 88 may be positioned adjacent to the opening 87 to support the circuit board 81 when attached to the housing 82. In one embodiment, opening 87 includes a notch 92 sized to receive the computing hardware 84 when the circuit board 81 is connected to the housing 82.
One or more arms 86 extend outward from the base 85 in a cantilever manner. The arms 86 may be rigid or may be flexible relative to the base 85. In one embodiment, four arms extend from the base 85 and each is flexible. In another embodiment, multiple arms 86 extend from the base 85 with one or more of the arms 86 being flexible and the others being rigid. The arms 86 form a receptacle 90 sized to extend around the entirety or a portion of the connector 150. One or more of the arms 86 may further include a flared end 89 to facilitate engagement with the connector 150 of the image forming device 100. Arms 86 may include a variety of shapes and configurations. The housing 82 may further include wings 91 that laterally extend outward to fit within the slot 36 in the retainer 35. The electrical connector 80 may be fixedly or movably attached to the cartridge 10. Embodiments of electrical connectors are disclosed in U.S. Pat. Nos. 7,258,558 and 7,272,336, each herein incorporated by reference.
One or more datum points are positioned to provide the proper alignment of the cartridge 10 within the image forming device 10. The datum points align the cartridge 10 along multiple dimensions during insertion into the image forming device 100. A first datum point is formed at the second end 30 of the alignment slot 28. A second datum point is formed along the edge 32 of the slot 28 on the side 16 of the extension 17. A third datum point includes a centerline of the alignment slot 28 on the front 14 of the extension 17.
The cartridge 10 is mounted within the image forming device 100 to transfer the toner for forming an image on a media sheet. After exiting the cartridge 10, the toner moves through a developer unit 250 and a photoconductive (PC) unit 260. As the toner is moving through these elements, a media sheet is being delivered to receive the toner.
A first toner transfer area 230 includes one or more imaging stations 240 that are aligned horizontally extending from the front 104 to the back 105 of the image forming device 100. Each imaging station 240 includes a cartridge 10, a developer unit 250, and a photoconductive unit 260. Each of the imaging stations 240 is mounted such that photoconductive (PC) drums 261 are substantially parallel. For purposes of clarity, the units 250, 260 are labeled on only one of the imaging stations 240. In one embodiment, each of the imaging stations 240 is substantially the same except for the color of toner.
The developer unit 250 includes a toner reservoir 251 to contain the toner. One or more agitating members may further be positioned within the reservoir 251 to move the toner. Developer unit 250 further includes a toner adder roll 252 that moves the toner supplied from the reservoir 251 to a developer roll 253. The photoconductive unit 260 includes in part a charging roll and the PC drum 261.
The charging roll 262 forms a nip with the PC drum 261, and charges the surface of the PC drum 261 to a specified voltage such as −1000 volts, for example. A laser beam from a printhead 106 is directed to the surface of the PC drum 261 and discharges those areas it contacts to form a latent image. In one embodiment, areas on the PC drum 261 illuminated by the laser beam are discharged to approximately −300 volts. The developer roll 253, which is coated with toner, forms a nip with the PC drum 261, then transfers toner to the PC drum 261 to form a toner image. A metering device such as a doctor blade assembly can be used to meter toner onto the developer roll prior to its transfer to the PC drum. The toner is attracted to the areas of the PC drum 261 surface discharged by the laser beam from the printhead 106.
An intermediate transfer mechanism (ITM) 230 is disposed adjacent to each of the imaging stations 240. In this embodiment, the ITM 230 is formed as an endless belt trained about drive roll 231, tension roll 232 and back-up roll 233. During image forming operations, the ITM 230 moves past the imaging stations 240 in a clockwise direction as viewed in
The ITM 230 rotates and collects the one or more toner images from the imaging stations 240 and then conveys the toner images to a media sheet at a second transfer area. The second transfer area includes a second transfer nip 235 formed between the back-up roll 233 and a second transfer roll 234.
Media sheets may originally be stored in a media input tray 220 positioned in a lower section of the device 100. The tray 220 is sized to contain a stack of media sheets that will receive color and/or monochrome images. The media input tray 220 is preferably removable for refilling. A control panel 221 may be located on the front 104 of the device 100. Using the control panel 221, the user is able to enter commands and generally control the operation of the image-forming device 100. For example, the user may enter commands to switch modes (e.g., color mode, monochrome mode), view the number of images printed, take the device 100 on/off line to perform periodic maintenance, and the like.
A media path 222 extends through the device 100 for moving the media sheets through the imaging process. Media sheets are initially stored in the input tray 220 or introduced through a manual feed 223. The sheets in the input tray 220 are picked by a pick mechanism 224 and moved into the media path 222. In this embodiment, the pick mechanism 224 includes a roll positioned at the end of a pivoting arm. The roll rotates to move the media sheets from input tray 220 towards the second transfer area. In one embodiment, the pick mechanism 224 is positioned in proximity (i.e., less than a length of a media sheet) to the second transfer area with the pick mechanism 224 moving the media sheets directly from the input tray 220 into the second transfer nip 235. For sheets entering through the manual feed 223, one or more rolls are positioned to move the sheet into the second transfer nip 235.
The media sheet receives the toner image from the ITM 230 as it moves through the second transfer nip 235. The media sheets with toner images are then moved along the media path 222 and into a fuser area 225. Fuser area 225 includes fusing rolls or belts 226 that form a nip to adhere the toner image to the media sheet. The fused media sheets then pass through exit rolls 227 that are located downstream from the fuser area 225. Exit rolls 227 may be rotated in either forward or reverse directions. In a forward direction, the exit rolls 227 move the media sheet from the media path 222 to an output area 228 at a top 107 of the device 100. In a reverse direction, the exit rolls 227 move the media sheet into a duplex path 229 for image formation on a second side of the media sheet.
A monocolor image forming device 100 may include a single imaging station 240, as compared to a color image forming device 100 that may include multiple imaging stations 240.
Receiving areas 101 are aligned along the frame 201 of the imaging unit 200 each sized to receive one of the cartridges 10. In this embodiment, four receiving areas 101 are horizontally aligned along the frame 201. Each of the receiving areas 101 is positioned adjacent to one of the developer units 250 and PC units 260. A wall 112 may separate a portion of the receiving area 101 that receives the extension 17 from the developer unit 250 and PC unit 260. Once fully inserted, the front shelf 25 (See
The receiving area 101 includes one or more engagement features 102 to engage with the cartridge engagement features 11 during insertion. The engagement features 102 include: an inlet 255 positioned to receive the toner from the cartridge outlet 50; a gear 254 that extends upward to mesh with the cartridge drive gear 60; a shutter actuation pin 256 that extends outward from the developer unit 250 to engage with the notch 53 to rotate the shutter 51; the electrical connector 150 that connects with the cartridge electrical connector 80; one or more guideways 108 that engage with the ribs 19; and an angled surface 109.
After a predetermined amount of insertion, the chamfer edge 18 that faces the front 14 contacts a retainer 111 on the frame 201. This contact causes the retainer 111 to slide relative to the frame 201 away from the receiving area 101 and extend over a section of the developer unit 250. In one embodiment, the retainer 111 moves over a post 257 that extends outward from the developer unit 250. Examples of a retainer are disclosed in U.S. patent Ser. No. ______(attorney docket no. 2006-0579.01/4670-550).
As the cartridge 10 continues insertion, the notch 53 on the shutter 51 contacts against the actuation pin 256 on the developer unit 250. Continued insertion causes the shutter 51 to rotate from the closed position to the open position. Prior to the shutter 51 moving to the open position, the outlet 50 on the cartridge 50 aligns with an inlet 255 on the developer unit 250. When the shutter 51 moves to the open position, any toner expelled through the outlet 50 is received in the inlet 255.
Spatially relative terms such as “under”, “below”, “lower”, “over”, “upper”, and the like, are used for ease of description to explain the positioning of one element relative to a second element. These terms are intended to encompass different orientations of the device in addition to different orientations than those depicted in the figures. Further, terms such as “first”, “second”, and the like, are also used to describe various elements, regions, sections, etc and are also not intended to be limiting. Like terms refer to like elements throughout the description.
As used herein, the terms “having”, “containing”, “including”, “comprising” and the like are open ended terms that indicate the presence of stated elements or features, but do not preclude additional elements or features. The articles “a”, “an” and “the” are intended to include the plural as well as the singular, unless the context clearly indicates otherwise.
The present invention may be carried out in other specific ways than those herein set forth without departing from the scope and essential characteristics of the invention. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.
