Developer Conveyance Unit for Monochrome Image Forming Devices
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Solution Overview
Problem
The challenge is to effectively utilize the dead space in electrophotographic image forming devices repurposed from full-color to monochrome models without increasing manufacturing costs or complexity, while maintaining the inexpensiveness of the monochrome devices.
Innovation Solution
An image forming apparatus with a holder for developer containers and a conveyance unit that can switch between two destinations, allowing for efficient developer distribution to two developer units, ensuring continuous operation even if one unit malfunctions or runs out of toner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a tandem-type full-color device structure is repurposed as a monochrome device by removing three colors of imaging units and their replenishment mechanisms, then the device can be produced at lower cost and share production lines with full-color devices, but dead space remains inside the casing that needs to be effectively utilized
Solution Approach 1:
The holder and conveyance unit originally designed for three-color toner containers are repurposed to hold and convey black toner containers. The conveyance unit can switch between destinations to serve either the first or second developer unit, making the system versatile and efficient use of existing components without adding new parts.
Solution Approach 2:
The imaging units are segmented into two separate first and second developer units, each capable of independently developing images. This segmentation allows the system to utilize the dead space by providing redundant developer units while maintaining the ability to share common replenishment infrastructure.
2Area of stationary object
If a spare toner container and conveyance mechanism are installed to utilize the dead space, then the space utilization improves, but the manufacturing cost and complexity increase
Solution Approach 1:
The holder and conveyance unit are designed to be universal, accommodating both the original three-color containers and black toner containers. The conveyance unit can switch between destinations to serve either developer unit, eliminating the need for separate dedicated conveyance mechanisms for each color.
Solution Approach 2:
The functions of holding and conveying toner are merged into a single integrated holder and conveyance unit system. This consolidation reduces the number of separate components needed and simplifies the manufacturing process while effectively utilizing the available space.
3Reliability
If redundancy is added to the toner supply system to ensure continuous operation, then reliability improves, but the device complexity and manufacturing cost increase
Solution Approach 1:
The developer system is segmented into multiple independent developer units (first and second developer units), each with its own toner container. This segmentation provides redundancy so that if one unit fails or runs out of toner, the other can continue operation without interrupting the overall system function.
Solution Approach 2:
The conveyance unit is designed with dynamic switching capability to redirect toner flow between different developer units based on operational needs. This dynamic adaptability allows the system to maintain reliability by switching between redundant units without requiring complex permanent dual-path infrastructure.
Data Source
AI summary
An image forming device that forms an image through exposure of any one of a plurality of photosensitive members to light, image developing, and image transfer. The image forming device includes a holder, a conveyance unit, a first developer unit, and a second developer unit. The holder holds one or more containers of developer and causes the developer to flow out from a container selected from the held containers. The conveyance unit conveys the developer from the container to a destination and can switch the destination between at least the first developer unit and the second developer unit. The first developer unit uses the developer to develop an electrostatic latent image formed on a first photosensitive member. The second developer unit uses the developer to develop an electrostatic latent image formed on a second photosensitive member. The image is the same color regardless of which developer unit is used.