BACKGROUND
1. Field of the Disclosure
The present disclosure relates generally to an electrophotographic image forming device and more particularly to a toner port shutter for a toner container of an electrophotographic image forming device.
2. Description of the Related Art
Image forming devices such as printers, copiers, facsimile machines, and the like, produce unusable “waste” or residual toner as a byproduct of an electrophotographic (EP) process. Ideally, all toner that is picked up by a photoconductive (PC) drum, such as from a developer roll in a single component development system or from a magnetic roll in a dual component development system, would be transferred onto a media sheet in a one-step toner transfer process or, prior to the media sheet, onto an intermediate transfer member (ITM) in a two-step toner transfer process. However, due to inefficiencies, some of the toner picked up by the PC drum does not get transferred to the media sheet or ITM. This residual or waste toner left on the PC drum after it has contacted the media sheet or ITM must be removed before the next image is formed otherwise print defects may occur. A cleaner blade or a cleaner brush is typically placed in contact with the PC drum to wipe and remove residual toner from its surface. A similar cleaning operation may be performed to remove residual toner from the ITM where a two-step toner transfer process is used.
Waste toner is typically delivered to and stored in a removable waste toner container to prevent the waste toner from releasing inside the image forming device. It is desired to prevent toner from leaking out of the waste toner container when the waste toner container is detached from the image forming device.
SUMMARY
A toner container according to one example embodiment includes a housing having a reservoir for holding toner. An inlet port is formed on the housing and is in fluid communication with the reservoir for receiving toner. A first shutter member and a second shutter member are positioned about the inlet port and are each pivotable between a closed position and an open position. When the first and second shutter members are in the closed positions, respective free ends of the first and second shutter members seal against each other and respective first face portions of the first and second shutter members seal against a perimeter of the inlet port such that the first and second shutter members block the inlet port. When the first and second shutter members are in the open positions, the first and second shutter members are pivoted away from the inlet port unblocking the inlet port. The first and second shutter members are biased toward the closed positions.
A shutter assembly for sealing an inlet port according to another example embodiment includes a first shutter member and a second shutter member positioned about the inlet port. The first and second shutter members are each pivotable between an open position and a closed position about respective pivot axes that extend parallel to each other on opposite sides of the inlet port. When the first and second shutter members are in the closed positions, respective free ends of the first and second shutter members seal against each other and respective first face portions of the first and second shutter members seal against a perimeter of the inlet port such that the first and second shutter members block the inlet port. When the first and second shutter members are in the open positions, the first and second shutter members are pivoted away from each other and from the inlet port unblocking the inlet port. The first and second shutter members are biased toward the closed positions.
A toner container according to another example embodiment includes a housing having a reservoir for holding toner and an inlet port having an opening in fluid communication with the reservoir for receiving toner. A first shutter member and a second shutter member are positioned about the opening and are each pivotable between an open position and a closed position about respective pivot axes that extend parallel to each other on opposite sides of the opening. When the first and second shutter members are in the closed positions, respective free ends of the first and second shutter members seal against each other and respective first face portions of the first and second shutter members seal against a perimeter of the opening such that the first and second shutter members each block a respective half of the opening. When the first and second shutter members are in the open positions, the first and second shutter members are pivoted away from the opening unblocking the opening. A biasing assembly biases the first and second shutter members toward the closed positions. The biasing assembly imparts a resultant force on each of the first and second shutter members when the first and second shutter members are in the closed positions along a force vector that is angled relative to a first plane defined by the opening such that a direction of the force vector is toward the opening and a central portion of said shutter member. The force vectors of the resultant forces on the first and second shutter members when the first and second shutter members are in the closed positions both lie in a second plane that is orthogonal to the first plane and that is positioned at a midpoint of each shutter member along an axial dimension of the pivot axes such that the first and second shutter members provide a substantially uniform sealing pressure against each other and against the perimeter of the opening when the first and second shutter members are in the closed positions.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of the present disclosure, and together with the description serve to explain the principles of the present disclosure.
FIG. 1 is a block diagram depiction of an imaging system according to one example embodiment.
FIG. 2 is a perspective view of an image forming device according to one example embodiment.
FIG. 3 is a perspective view of the image forming device shown in FIG. 2 with a front access door opened and a waste toner container detached from the image forming device.
FIG. 4 is a perspective view of the waste toner container shown in FIG. 3 according to one example embodiment.
FIGS. 5A and 5B are perspective views illustrating a shutter assembly in a closed position and an open position, respectively, relative to an inlet port of the waste toner container according to one example embodiment.
FIGS. 6A and 6B are perspective views of a shutter member of the shutter assembly shown in FIGS. 5A and 5B according to one example embodiment.
FIG. 6C is a bottom plan view of the shutter member shown in FIGS. 6A and 6B according to one example embodiment.
FIG. 6D is a side elevation view of the shutter member of shown in FIGS. 6A-6C according to one example embodiment.
FIG. 7 is a perspective view of the shutter assembly including a biasing mechanism according to another example embodiment.
FIGS. 8A and 8B are side elevation views of the shutter assembly shown in FIGS. 5A and 5B in the closed and open positions, respectively.
FIGS. 9A and 9B are top plan views of the shutter assembly shown in FIGS. 5A and 5B in the closed and open positions, respectively.
FIG. 10 is a perspective cross-sectional view of the shutter assembly shown in FIGS. 5A and 5B illustrating clearance between trunions and trunion retainers of the shutter assembly according to one example embodiment.
FIG. 11 is a perspective view of the shutter assembly shown in FIGS. 5A and 5B in the open position with a waste toner outlet inserted into the inlet port of the waste toner container according to one example embodiment.
FIGS. 12A and 12B are a top plan and a side elevation view, respectively, of the shutter assembly including a biasing mechanism according to another example embodiment.
FIGS. 13A and 13B are top cross-sectional views illustrating an actuator of the waste toner container that opens a shutter of the waste toner outlet as the waste toner container is installed in the image forming device according to one example embodiment.
DETAILED DESCRIPTION
In the following description, reference is made to the accompanying drawings where like numerals represent like elements. The embodiments are described in sufficient detail to enable those skilled in the art to practice the present disclosure. It is to be understood that other embodiments may be utilized and that process, electrical and mechanical changes, etc., may be made without departing from the scope of the present disclosure. Examples merely typify possible variations. Portions and features of some embodiments may be included in or substituted for those of others. The following description, therefore, is not to be taken in a limiting sense and the scope of the present disclosure is defined only by the appended claims and their equivalents.
Referring now to the drawings and particularly to FIG. 1, there is shown a diagrammatic depiction of an imaging system 20 according to one example embodiment. As shown, imaging system 20 may include an image forming device 22 and a computer 24. Image forming device 22 communicates with computer 24 via a communications link 26. As used herein, the term “communications link” is used to generally refer to any structure that facilitates electronic communication between multiple components, and may operate using wired or wireless technology and may include communications over the Internet.
In the embodiment shown in FIG. 1, image forming device 22 is shown as a multifunction machine that includes a controller 28, a print engine 30, a laser scan unit (LSU) 31, an imaging unit 32, a toner cartridge 35, a waste toner container 100, a user interface 37, a media feed system 38, a media input tray 40 and a scanner system 41. Image forming device 22 may communicate with computer 24 via a standard communication protocol, such as, for example, universal serial bus (USB), Ethernet or IEEE 802.xx. A multifunction machine is also sometimes referred to in the art as an all-in-one (AIO) unit. Those skilled in the art will recognize that image forming device 22 may be, for example, an electrophotographic printer/copier including an integrated scanner system 41 or a standalone printer.
Controller 28 includes a processor unit and associated memory 29 and may be formed as one or more Application Specific Integrated Circuits (ASICs). Memory 29 may be any volatile or non-volatile memory or combinations thereof such as, for example, random access memory (RAM), read only memory (ROM), flash memory, and/or non-volatile RAM (NVRAM). Alternatively, memory 29 may be in the form of a separate electronic memory (e.g., RAM, ROM, and/or NVRAM), a hard drive, a CD or DVD drive, or any memory device convenient for use with controller 28. Controller 28 may be, for example, a combined printer and scanner controller.
In the example embodiment illustrated, controller 28 communicates with print engine 30 via a communications link 50. Controller 28 communicates with imaging unit 32 and processing circuitry 44 thereon via a communications link 51. Controller 28 communicates with toner cartridge 35 and processing circuitry 45 thereon via a communications link 52. Controller 28 communicates with media feed system 38 via a communications link 54. Controller 28 communicates with scanner system 41 via a communications link 55. User interface 37 is communicatively coupled to controller 28 via a communications link 56. Processing circuitry 44, 45 may provide authentication functions, safety and operational interlocks, operating parameters and usage information related to imaging unit 32 and toner cartridge 35, respectively. Each of processing circuitry 44, 45 includes a processor unit and associated electronic memory. As discussed above, the processor may include one or more integrated circuits in the form of a microprocessor or central processing unit and may be formed as one or more Application-specific integrated circuits (ASICs). The memory may be any volatile or non-volatile memory or combination thereof or any memory device convenient for use with processing circuitry 44, 45. Controller 28 serves to process print data and to operate print engine 30 during printing, as well as to operate scanner system 41 and process data obtained via scanner system 41.
Controller 28 oversees the functioning of the image forming device 22 including toner cartridge 35, imaging unit 32, LSU 31, user interface 37, feeding of media from removable media input tray 40, and the movement of the media along media path(s) within image forming device 22. Toner cartridge 35 and/or imaging unit 32 may also contain its own associated memory as discussed above.
Computer 24, which is optional, may be, for example, a personal computer, network server, tablet computer, smartphone or other electronic device, including memory 60, such as volatile and/or non-volatile memory, an input device 62, such as a keyboard, and a display, such as a monitor 64. Computer 24 further includes a processor, input/output (I/O) interfaces, and may include at least one mass data storage device, such as a hard drive, a CD-ROM and/or a DVD unit (not shown).
Computer 24 includes in its memory a software program including program instructions that function as an imaging driver 66, e.g., printer/scanner driver software, for image forming device 22. Imaging driver 66 is in communication with controller 28 of image forming device 22 via communications link 26. Imaging driver 66 facilitates communication between image forming device 22 and computer 24. One aspect of imaging driver 66 may be, for example, to provide formatted print data to image forming device 22, and more particularly, to print engine 30, to print an image. Another aspect of imaging driver 66 may be, for example, to facilitate collection of scanned data.
In some circumstances, it may be desirable to operate image forming device 22 in a standalone mode. In the standalone mode, image forming device 22 is capable of functioning without computer 24. Accordingly, all or a portion of imaging driver 66, or a similar driver, may be located in controller 28 of image forming device 22 so as to accommodate printing and scanning functionality when operating in the standalone mode.
Print engine 30 includes laser scan unit 31, toner cartridge 35, imaging unit 32, and a fuser 39, all mounted within image forming device 22. The imaging unit 32 is removably mounted in image forming device 22 and includes a developer unit 34 that houses a toner sump and a toner development system. In one embodiment, the toner development system utilizes what is commonly referred to as a single component development system. In this embodiment, the toner development system includes a toner adder roll that provides toner from the toner sump of developer unit 34 to a developer roll. A doctor blade provides a metered uniform layer of toner on the surface of the developer roll. In another embodiment, the toner development system utilizes what is commonly referred to as a dual component development system. In this embodiment, toner in the toner sump of developer unit 34 is mixed with magnetic carrier beads. The magnetic carrier beads may be coated with a polymeric film to provide triboelectric properties to attract toner to the carrier beads as the toner and the magnetic carrier beads are mixed in the toner sump. In this embodiment, developer unit 34 includes a magnetic roll that attracts the magnetic carrier beads having toner thereon to the magnetic roll through the use of magnetic fields. Imaging unit 32 also includes a cleaner unit 33 that houses a photoconductive drum and a waste toner removal system.
The electrophotographic process is well known in the art and will, therefore, be briefly described herein. Laser scan unit 31 creates a latent image on the photoconductive drum in the cleaner unit 33. Toner is transferred from the toner sump in developer unit 34 to the latent image on the photoconductive drum by the developer roll (in the case of a single component development system) or by the magnetic roll (in the case of a dual component development system) to create a toned image. The toned image is subsequently transferred to a media sheet from media input tray 40 for printing. Toner may be transferred directly to the media sheet by the photoconductive drum in a one-step transfer system or by an intermediate transfer member (ITM) that receives the toner from the photoconductive drum in a two-step transfer system. The toner image is bonded to the media sheet in the fuser 39 and then sent to an output location or to one or more finishing options such as a duplexer, a stapler or hole punch. Toner remnants are removed from the photoconductive drum (and, in the case of a two-step transfer system, the intermediate transfer member) by the waste toner removal system of cleaner unit 33 and are delivered to and stored in waste toner container 100 to prevent the residual toner from releasing inside the image forming device 22. In one example embodiment, waste toner container 100 is detachably attached to image forming device 22. Further, in color electrophotographic image forming devices, multiple toner cartridges, developer units, photoconductive drums and cleaner units may be required for each of the different color toners (e.g., cyan, yellow, magenta and black colored toner). A common waste toner container may be provided for storing waste toner from each of cleaner units for the different color toners. Alternatively, a separate waste toner container may be provided for each of the different color toners.
FIG. 2 illustrates an example of image forming device 22 having a housing 70 having a front 72, first and second sides 74, 76, a rear 78, a top 80 and a bottom 82. Ventilation openings, such as vents 84 on first side 74 are provided. A media output area 86 is provided on top 80 for printed media exiting image forming device 22. A door 88 is provided on the front 72 of image forming device 22. Door release 90 is provided near a top edge 88-1 of door 88 and is used to open door 88 to allow user access into the interior of image forming device 22 for replenishing supply items such as toner cartridges. Side access door 92 is provided on first side 74 and covers portions of the media path and various feed roll pairs provided in image forming device 22. Door release 93 is provided near a top edge 92-1 of side access door 92 and is used to open side access door 92 when clearing a media jam from the media path within image forming device 22. Removable media tray 40 for providing media to be printed is slidably inserted into image forming device 22 below door 88.
User interface 37, comprising a display 57 and a key panel 58, may be located on the front 72 of housing 70. Using the user interface 37, a user is able to enter commands and generally control the operation of the image forming device 22. For example, the user may enter commands to switch modes (e.g., color mode, monochrome mode), view the number of images printed, take the image forming device 22 on/off line to perform periodic maintenance, and the like.
FIG. 3 illustrates image forming device 22 with door 88 in a lowered, open position exposing interior components of image forming device 22, such as toner cartridges 35a, 35b, 35c and 35d, and with waste toner container 100 detached from image forming device 22. In the embodiment illustrated in FIG. 3, image forming device 22 is a color electrophotographic image forming device. Waste toner collected by the cleaner units in image forming device 22 for each of the different color toners are sent to waste toner container 100 through respective waste toner outlets 95. Each waste toner outlet 95 extends toward front 72 of housing 70 of image forming device 22. A similar waste toner outlet may also be provided to deliver waste toner removed from the ITM into waste toner container 100.
In FIG. 4, a perspective view of waste toner container 100 including a plurality of waste toner inlet ports 120 is illustrated. Waste toner outlets 95 of image forming device 22 are received by respective waste toner inlet ports 120 of waste toner container 100 when waste toner container 100 is installed in image forming device 22 to allow waste toner to be deposited into waste toner container 100. Waste toner container 100 includes a housing 105 having an enclosed waste toner reservoir for holding a quantity of waste toner therein. Housing 105 includes a top 106, a bottom 107, opposed first and second walls 108, 109, and side walls 110a, 110b forming the enclosed waste toner reservoir. Waste toner inlet ports 120 define respective through holes or openings 122 in first wall 108 of housing 105 through which respective waste toner outlets 95 of image forming device 22 are inserted into the waste toner reservoir for depositing waste toner therein. Foam seals 125 are provided on the outer side of first wall 108 about each opening 122. Each foam seal 125 has an opening 126 that is sized to sealably receive a respective waste toner outlet 95 to prevent the escape of waste toner during transport thereof through waste toner outlets 95 into the waste toner reservoir when waste toner container 100 is installed in image forming device 22.
With reference to FIGS. 5A and 5B, waste toner container 100 includes a shutter assembly 150 disposed on an inner side of first wall 108 about each opening 122 for blocking a respective inlet port 120. Shutter assembly 150 is shown as a split-shutter assembly having a pair of shutter members including a first shutter member 155a and a second shutter member 155b that each forms a half of shutter assembly 150. In one example embodiment, first and second shutter members 155a, 155b are substantially symmetrical or mirror images of each other. Hereinafter, any one of first and second shutter members 155a, 155b may be referred to as a shutter member 155. First and second shutter members 155a, 155b are disposed about opening 122 of inlet port 120 and are each pivotable between a closed position, as shown in FIG. 5A, to prevent toner leakage when waste toner container 100 is removed from image forming device 22, and an open position, as shown in FIG. 5B, when waste toner outlet 95 mates with inlet port 120 as waste toner container 100 is installed in image forming device 22. First shutter member 155a is pivotable about a first pivot axis 157a and second shutter member 155b is pivotable about a second pivot axis 157b. First and second pivot axes 157a, 157b are substantially parallel to each other on opposite sides of opening 122 of inlet port 120. In the example embodiments discussed herein, the features of the shutter assembly 150 of each inlet port 120 are substantially the same.
First and second shutter members 155a, 155b are described in further detail with reference to FIGS. 6A-6D. In one example form, each shutter member 155a, 155b has a substantially semi-circular shaped body 160 having a first face portion 162, a second face portion 164 opposite the first face portion 162, and a free end 166. First face portion 162 includes a rim 168 that forms a sealing lip. In one example, rim 168 may be integrally formed as a unitary piece with body 160. In another example, rim 168 may be made of compliant material and attached to first face portion 162. Rim 168 may be constructed of any suitable material for providing sealing, such as any suitable plastic or compliant material. When first and second shutter members 155a, 155b are in the closed positions, respective free ends 166 thereof contact and seal against each other, and respective rims 168 contact and seal against a surrounding perimeter 124 of opening 122 of inlet port 120 (see FIG. 5B) such that first and second shutter members 155a, 155b each blocks a respective half of opening 122. In the open positions, first and second shutter members 155a, 155b are pivoted away from inlet port 120 unblocking opening 122. Each of the first and second shutter members 155a, 155b includes a trunion 170 extending along an axial dimension of its respective pivot axis 157a, 157b and having opposed ends that are received within corresponding trunion retainers 128 (see FIGS. 5A and 5B) provided on the inner side of first wall 108. Low friction restraints 130 are provided at opposite ends of each trunion 170 to limit axial movement of shutter member 155. Opposite ends of each trunion 170 may have tapered tips (see FIG. 6C) to reduce frictional contact between trunion 170 and trunion restraints 130. In some embodiments, a trunion stiffener or rib 171 adds stiffness and strength to each trunion 170 and shutter member 155.
With further reference to FIGS. 5A-6D, first and second shutter members 155a, 155b are biased toward their closed positions by a biasing assembly 180. In one example embodiment, biasing assembly 180 includes a first biasing mechanism 182a coupled between first shutter member 155a and a portion of housing 105 surrounding the perimeter 124 of opening 122 of inlet port 120 and a second biasing mechanism 182b coupled between second shutter member 155b and the portion of housing 105 surrounding the perimeter 124 of opening 122 of inlet port 120. Each of the first and second shutter members 155a, 155b is shown having a pair of arms 172a, 172b extending outwardly from second face portion 164 proximate to its respective pivot axis 157a, 157b and positioned opposite each other relative to a centerline 174 of shutter member 155. In the example embodiment illustrated, each of arms 172a, 172b includes an arcuate gusset 176 that extends from a respective free end 178a, 178b of arms 172a, 172b towards second face portion 164 parallel to each other, terminating at a central portion 177 of shutter member 155. Gussets 176 add strength and rigidity to arms 172a, 172b.
In the embodiment illustrated in FIGS. 5A and 5B, first and second biasing mechanisms 182a, 182b each includes a compound tension spring 184 having a first spring coil 184a and a second spring coil 184b connected in series at an intermediate portion 184c therebetween. Intermediate portion 184c of compound tension spring 184 is inserted through spring anchors 179a, 179b formed at free ends 178a, 178b of arms 172a, 172b to attach compound tension spring 184 to arms 172a, 172b. Opposed ends 184d, 184e of compound tension spring 184 are attached to respective spring mounts 129a, 129b that are provided on the inner side of first wall 108 opposite to each other relative to arms 172a, 172b and opening 122 of inlet port 120.
Although the example embodiment illustrated in FIGS. 5A and 5B shows each of the first and second shutter members 155a, 155b having two arms 172a, 172b coupled to first or second biasing mechanisms 182a, 182b, it will be understood that each shutter member 155 may include any number of arms for coupling with a respective biasing mechanism 182. In addition, it is understood that biasing assembly 180 may use other biasing mechanisms or any resilient member for biasing first and second shutter members 155a, 155b toward the closed positions. For example, in an alternative example embodiment illustrated in FIG. 7, each of first and second biasing mechanisms 182a, 182b includes a first tension spring 183 and a second tension spring 185. First tension spring 183 has a first end 183a attached to spring anchor 179a of arm 172a and a second end 183b attached to spring mount 129a. Second tension spring 185 has a first end 185a attached to spring anchor 179b of arm 172b and a second end 185b attached to spring mount 129b opposite spring mount 129a relative to arms 172a, 172b. The spring forces of first and second tension springs 183, 185 may be substantially equal and are designed to provide the biasing force needed to bias shutter member 155 towards the closed position.
In one example embodiment, each of the first and second biasing mechanisms 182a, 182b is arranged such that when first and second shutter members 155a, 155b are in the closed positions, each of the first and second biasing mechanisms 182a, 182b imparts a resultant force on a respective shutter member 155a, 155b along a force vector that is angled relative to a plane defined by the perimeter 124 of inlet port 120 such that a direction of the force vector is toward opening 122 of inlet port 120 and central portion 177 of first or second shutter member 155a, 155b. Such resultant force may be achieved by controlling the angle of first and second spring coils 184a, 184b connected between shutter member 155 and the perimeter 124 of inlet port 120.
In general, the angle of first and second spring coils 184a, 184b are controlled by the height of spring anchors 179a, 179b of arms 172a, 172b relative to second face portion 164 and the positions of spring anchors 179a, 179b relative to spring attachment points around the perimeter 124 of inlet port 120 defined by the locations of spring mounts 129a, 129b. As an example, consider second spring coil 184b of first shutter member 155a when viewed from the side as shown in FIG. 8A. As shown, the point at which second spring coil 184b is attached to spring anchor 179b of arm 172b is at a height H relative to second face portion 164 and the point at which second spring coil 184b is attached to spring mount 129b is at a distance D from pivot axis 157a such that second spring coil 184b connected between spring anchor 179b and spring mount 129b is at angle θ relative to second face portion 164. Distance D may be about one-half the distance W between pivot axis 157 and free end 166. When viewed from the top as shown in FIG. 9A, second spring coil 184b is at an angle φ relative to centerline 174. As a result, second spring coil 184b imparts a spring force F2 having components F2x, F2y, F2z along the x, y and z axes, respectively. First spring coil 184a is arranged in a similar manner to that of second spring coil 184b on the other side of centerline 174 (i.e., substantially symmetrical relative to second spring coil 184b about centerline 174) and imparts a spring force F1 having components F1x, F1y, F1z along the x, y, and z axes, respectively, and having a force magnitude substantially equal to that of spring force F2. It is noted that z-component F2z of spring force F2 may be seen to be going out of the sheet on which FIG. 8A appears and z-component F1z of spring force F1 may be seen to be going into the sheet on which FIG. 8A appears. On the other hand, y-components F1y, F2y of spring forces F1 and F2, respectively, may be seen to be going into the sheet on which FIG. 9A appears.
Having the arrangement of first biasing mechanism 182a shown in FIGS. 8A and 9A with first shutter member 155a in the closed position, a resultant force R1 acts on first shutter member 155a which is the result of combining forces F1 and F2 acting on first shutter member 155a. The angled spring trajectories of first and second spring coils 184a, 184b introduce force components that are in directions along pivot axis 157a, as depicted by z-components F1z, F2z, but are opposite to each other thereby substantially cancelling each other out and leaving only the x and y components of forces F1 and F2 to contribute to the magnitude and direction of resultant force R1. Any small net imbalance of force along the z direction is reacted at restraints 130 and the tips of trunion 170. The force vector of resultant force R1 passes through central portion 177 of first shutter member 155a. In a similar manner, second biasing mechanism 182b of second shutter member 155b imparts a resultant force R2 which is the result of combining forces F1 and F2 acting on second shutter member 155b due to first and second spring coils 184a, 184b connected thereto. In one embodiment, when first and second shutter members 155a, 155b are in the closed positions, the force vectors of resultant forces R1 and R2 both lie in the same plane that is orthogonal to the plane defined by opening 122 and/or the perimeter 124 of inlet port 120 and that is positioned along centerlines 174. By having biasing assembly 180 impart resultant forces R1 and R2 on first and second shutter members 155a, 155b, respectively, first and second shutter members 155a, 155b provide a substantially uniform sealing pressure against each other and against the perimeter 124 of inlet port 120 when first and second shutter members 155a, 155b are in the closed positions. In particular, the angle of first and second spring coils 184a, 184b as controlled by the locations of spring anchors 179a, 179b on first and second shutter members 155a, 155b and spring mounts 129a, 129b on the perimeter 124 of inlet port 120 cause the sealing force of free ends 166 against each other and the sealing force of rims 168 against the perimeter 124 of inlet port 120 to be substantially equal, thereby providing effective sealing against the escape of waste toner. In one embodiment, extra clearance is provided between trunion 170 and trunion retainers 128 as shown in FIG. 10 that allows for biasing assembly 180 to pull first and second shutter members 155a, 155b against each other along free ends 166 so that they seal against toner escape.
When waste toner container 100 is installed in image forming device 22, waste toner outlet 95 is inserted through opening 122 of inlet port 120 and into the waste toner reservoir, as shown in FIG. 11, engaging and moving first and second shutter members 155a, 155b from the closed positions to the open positions. The length of, and volume of space occupied by, each of first and second spring coils 184a, 184b is minimized by angling them from spring mounts 129a, 129b inwardly towards centerline 174, overlapping with shutter member 155 as can be seen in FIG. 9A. In order to allow shutter member 155 to move between the closed and open positions without interference from first and second spring coils 184a, 184b, each of first and second shutter members 155a, 155b are provided with crescent-shaped notches 187 formed along peripheral edges of second face portion 164 (see FIG. 6A). In general, notches 187 are sized and shaped such that first and second spring coils 184a, 184b travel within respective notches 187 of shutter member 155 as shutter member 155 moves between the closed and open positions. For example, notches 187 may conform to the shape of first and second spring coils 184a, 184b and to the path of motion followed by first and second spring coils 184a, 184b as shutter member 155 moves between the closed and open positions. As a result, shutter member 155 and first and second coils 184a, 184b connected thereto are free to move without interfering with each other.
In the example embodiment illustrated, when each of the first and second shutter members 155a, 155b is in the open position, first and second spring coils 184a, 184b lay across trunion 170 (see also FIGS. 8B and 9B). Although first and second spring coils 184a, 184b are stretched when first and second shutter members 155a, 155b are in the open positions, tension is adjusted by allowing first and second spring coils 184a, 184b to bend as central portions thereof are seated over trunion 170 such that a large increase of force acting on shutter member 155 (relative to the sealing force in the closed position) that biases the shutter member 155 towards the closed position is prevented. FIG. 9B shows first and second spring coils 184a, 184b of first biasing mechanism 182a imparting a resultant force R3 on first shutter member 155a and first and second spring coils 184a, 184b of second biasing mechanism 182b imparting a resultant force R4 on second shutter member 155b. Resultant forces R3 and R4 are generally coplanar with resultant forces R1 and R2. Considering, for example, resultant force R4 shown in FIG. 8B, a relatively large vector component R4x of resultant force R4 is the horizontal component (as viewed in FIG. 8B) which acts to push trunion 170 against its trunion retainer 128, while a relatively small vector component R4y of resultant force R4 is the vertical component (as viewed in FIG. 8B) which acts to rotate and bias shutter member 155 toward the closed position. In other example embodiments, each resultant force R3 and R4 may have an almost zero vector component acting to bias shutter member 155 towards the closed position. For example, in another example embodiment, illustrated in FIGS. 12A and 12B, trunions 170 are shortened so that trunion retainers 128 and restraints 130 are located closer to the peripheral edges of shutter member 155 and arms 172a, 172b are moved outward farther away from centerline 174 such that compound tension spring 184 can lay flat against the portion of housing 105 surrounding perimeter 124 outside tunion retainers 128 when shutter member 155 is fully opened. In this embodiment, when shutter member 155 is fully opened, each resultant force R3′ and R4′ has nearly its full value acting to push trunion 170 against its trunion retainer 128 and nearly zero vector component acting to bias shutter member 155 towards the closed position. In these example embodiments, the magnitude of each of resultant forces R3 and R4 acting on first and second shutter members 155a, 155b when in the open positions may be slightly greater than, equal to, or even substantially less than the magnitude of the resultant forces R1 or R2 acting on the shutter member 155 in the closed position.
First and second shutter members 155a, 155b push against waste toner outlet 95 substantially equally from opposite sides of waste toner outlet 95, as depicted by forces FL and FR in FIG. 11, such that there is no side-loading on waste toner outlet 95 and consequently an approximately zero net side-force exerted by shutter assembly 150 on waste toner outlet 95 thereby reducing the likelihood of bending or deforming waste toner outlet 95 over time. The approximately zero net side-force exerted by shutter assembly 150 on waste toner outlet 95 also reduces the likelihood of biasing imaging unit 32 sideways, which could misalign imaging unit 32 relative to the printed media (or the ITM where a two-step toner transfer process is used) and affect print registration and quality. When waste toner outlet 95 is fully inserted into inlet port 120 and shutter assembly 150 is fully opened, first and second shutter members 155a, 155b are positioned substantially parallel to the direction of insertion of waste toner outlet 95 into inlet port 150 such that first and second shutter members 155a, 155b apply approximately zero force on waste toner outlet 95 along the direction of insertion. As a result, shutter assembly 150 does not apply a residual force in a direction that would push waste toner outlet 95 out of inlet port 120.
When waste toner container 100 is detached from image forming device 22, waste toner outlet 95 is dislodged out of inlet port 120 and first and second shutter members 155a, 155b return to their closed positions due to the biasing forces of biasing assembly 180. Typically, first and second shutter members 155a, 155b close simultaneously when waste toner container 100 is removed from image forming device 22 as the removal of waste toner outlet 95 from inlet port 120 releases the first and second shutter members 155a, 155b simultaneously. In order to account for the possibility of first and second shutter members 155a, 155b closing at different times, a safety mechanism is provided to prevent one shutter member from blocking closure of the other shutter member. In one example embodiment, each of first and second shutter members 155a, 155b includes one or more guides 189 projecting from second face portion 164 thereof for facilitating movement of first and second shutter members 155a, 155b toward the closed positions. In the example shown, each guide 189 has an arcuate contact surface 189a extending from free end 166, with the arcuate contact surfaces 189a of guides 189 of first shutter member 155a arranged to slide against corresponding arcuate contact surfaces 189a of guides 189 of second shutter member 155b during instances where first and second shutter members 155a, 155b move toward the closed positions at different times. More particularly, when one of the first and second shutter members 155a, 155b lags behind the other in reaching the closed position, guides 189 of the lagging shutter member 155 slide against corresponding guides 189 of the first-to-close shutter member 155 until the lagging shutter member 155 reaches its closed position. Accordingly, the shutter member 155 that first reaches the closed position is prevented from blocking the lagging shutter member 155 from reaching its closed position. In one example, guides 189 may be made of material that provides sufficiently low coefficient of friction such that the biasing force of biasing assembly 180 may allow one shutter member 155 to slide against the other shutter member 155 via guides 189 and reach the closed position. In addition, the amount of clearance between trunion 170 and trunion retainers 128 may be selected such that guides 189 do not contact each other too early as biasing assembly 180 pulls the first and second shutter members 155a, 155b toward each other before the closed position is reached.
With each of the first and second shutter members 155a, 155b forming a half of shutter assembly 150, first and second shutter members 155a, 155b swing through a small volume of space within the waste toner reservoir relative to the space that would be occupied by a conventional single swinging shutter member sealing opening 122 thereby permitting the use of an actuation finger in waste toner container 100 for actuating waste toner outlet 95. FIG. 13A illustrates an example top cross-sectional view of waste toner outlet 95 when waste toner container 100 is detached from image forming device 22 and FIG. 13B illustrates waste toner outlet 95 inserted into inlet port 120 of waste toner container 100 when waste toner container 100 is installed in image forming device 22. In the example shown, waste toner outlet 95 includes a toner discharge pipe 96 having a hole 97 provided in a lower portion thereof through which waste toner exits waste toner outlet 95, and a shutter 98 disposed within toner discharge pipe 96 and having an opening 99 provided in a lower portion thereof. A drive mechanism (not shown) drives and rotates an auger mechanism 91 within waste toner outlet 95 to move waste toner collected by each cleaner unit 33 towards the free end of waste toner outlet 95. Shutter 98 is slidably movable within toner discharge pipe 96 between a closed position and an open position. In the closed position, shutter 98 blocks hole 97 of toner discharge pipe 96 to prevent toner from escaping waste toner outlet 95 when waste toner container 100 is removed from image forming device 22 as shown in FIG. 13A. Shutter 98 is biased toward the closed position blocking waste toner outlet 95 such as, for example, by one or more compression springs 93. In the open position shown in FIG. 13B, opening 99 of shutter 98 aligns with hole 97 of toner discharge pipe 96 to permit waste toner to exit waste toner outlet 95 through opening 99 and hole 97, and be deposited into the waste toner reservoir of waste toner container 100, A protrusion 132 protrudes within the waste toner reservoir in a direction toward opening 122 of inlet port 120. As waste toner outlet 95 is inserted into inlet port 120 of waste toner container 100, protrusion 132 provided in waste toner container 100 presses shutter 98 of waste toner outlet 95, causing shutter 98 to slide from the closed position to the open position. When shutter 98 of waste toner outlet 95 reaches the open position, opening 99 of shutter 98 aligns with hole 97 of toner discharge pipe 96 to permit waste toner to transfer from cleaner unit 33 of image forming device 22 to waste toner container 100. Protrusion 132 protrudes at a length that is clear from engagement with first and shutter members 155a, 155b as the shutter members move between the closed and open positions, and that is enough to move shutter 98 of waste toner outlet 95 from the closed position to the open position at which opening 99 of shutter 98 aligns with hole 97 of toner discharge pipe 96.
The above example embodiments have been described with respect to a removable waste toner container for image forming device 22. It will be appreciated, however, that the concepts and teachings described herein may also be used in other sub-systems of image forming device 22.
The foregoing description illustrates various aspects and examples of the present disclosure. It is not intended to be exhaustive. Rather, it is chosen to illustrate the principles of the present disclosure and its practical application to enable one of ordinary skill in the art to utilize the present disclosure, including its various modifications that naturally follow. All modifications and variations are contemplated within the scope of the present disclosure as determined by the appended claims. Relatively apparent modifications include combining one or more features of various embodiments with features of other embodiments.
Patent Grant
9933727
