Developer Cartridge Filling Port Cap Design for Safe Refilling

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Solution Overview

Problem

Existing developer cartridges face challenges in safely detaching sealing caps without damaging the filling ports, leading to potential toner leakage and difficulties in distinguishing between new and recycled cartridges, which complicates the recycling process and requires frequent component checks.

Innovation Solution

The developer cartridge design includes a cylindrical wall portion with a protruding end surface and a closure member that is initially pressed in and then ultrasonically welded after refilling, allowing for safe detachment and reattachment without damaging the port, and using different cap members for initial and recycled cartridges to maintain sealing performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the sealing cap is bonded to the toner filling port by an adhesive agent, then the sealing cap is firmly fixed to prevent toner leakage, but the sealing cap becomes difficult to detach from the filling port

Engineering Contradiction:

Improvesealing performanceVSAvoiddetachability of cap

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The filling port structure is segmented into multiple components: the filling port body, a cap, and a cylindrical wall portion. This segmentation allows the cap to be firmly sealed during use while enabling easy detachment when refilling is needed, resolving the contradiction between reliable sealing and ease of operation.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the sealing cap is pressingly fitted in the toner filling port, then the sealing cap prevents toner leakage, but the filling port may be damaged when the cap is detached

Engineering Contradiction:

Improvesealing performanceVSAvoiddamage to filling port

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The cylindrical wall portion protruding from the filling port serves as a protective structure that cushions and guides the cap during insertion and detachment. This pre-designed protective feature prevents direct damage to the filling port when the cap is pressed in or removed, allowing reliable sealing without harmful effects.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of operation

If the cap is forced to be removed from the filling port with the cap fit on the periphery of the filling port, then the cap can be detached, but the periphery of the filling port is damaged resulting in deteriorated sealing performance

Engineering Contradiction:

Improvedetachability of capVSAvoidsealing performance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The cylindrical wall portion acts as an intermediary structure between the cap and the filling port. During cap detachment, this intermediary structure guides and supports the cap, preventing it from being forced off the periphery of the filling port. This ensures easy detachment while maintaining the integrity and sealing performance of the filling port.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of manufacture

If a cap is pressed again in the damaged filling port after refilling toner, then the filling port can be closed, but toner leakage occurs from the damaged part

Engineering Contradiction:

Improverefilling processVSAvoidsealing performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The cylindrical wall portion provides continuous protection during both initial cap installation and refilling operations. By guiding the cap into proper alignment and preventing peripheral damage, this pre-designed structure ensures that the filling port maintains its integrity throughout the refilling process, enabling easy manufacture while preventing toner leakage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enables safe and efficient refilling of developer cartridges without port damage, allows for easy identification of recycled cartridges, and maintains sealing performance after refilling, thereby simplifying the recycling process and ensuring reliable operation.

Implementation Method 1

the closure member is initially pressed in and then ultrasonically welded after refilling

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS7486905B2Developer cartridge including developer filling port cap and recycling method thereof

Publication Date: 2009.02.03 BROTHER KOGYO KK

AI summary

A cartridge includes: a casing having a wall defining a developer accommodating portion inside the casing, a filling port being formed through the wall in fluid communication with the developer accommodating portion; a cylindrical wall portion formed on the wall at a circumferential edge of the filling port and protruding from the wall outside the casing, the cylindrical wall portion having an inner peripheral surface, an outer peripheral surface, and an end surface positioned between the inner peripheral surface and the outer peripheral surface; a closure member which is fitted in the cylindrical wall portion, while being in contact with the inner peripheral surface of the cylindrical wall portion, to close the filling port; and a protruding portion that is provided on at least one of the end surface and the closure member at its contact portion between the end surface and the closure member and that protrudes toward the other one of the end surface and the closure member.