Drum Unit Toner Replenishment Integration

Solution Overview

Problem

Conventional image forming apparatuses require a separate toner replenishing device, leading to increased size of the drum unit and the apparatus.

Innovation Solution

The design includes a drum unit with a movable toner cartridge that can be attached to the housing, featuring a photosensitive drum, developing unit with a magnetic roller, and augers for toner and carrier circulation, allowing direct toner replenishment from the cartridge to the developer container, eliminating the need for a separate toner replenishing device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a separate toner replenishing device is provided to replenish toner from the toner cartridge to the developer container, then the toner replenishment function is achieved, but the size of the drum unit and image forming apparatus increases

Engineering Contradiction:

Improvetoner replenishment functionVSAvoidsize of drum unit

Core Design Contradiction:

ProductivityVSVolume of moving object

Solution Approach 1:

The patent merges the toner replenishment function into the drum unit by integrating the toner cartridge directly with the developer container. The toner cartridge is configured to be attachable to the drum unit, allowing direct replenishment of toner to the developer container without requiring a separate replenishing device, thus reducing the overall size while maintaining the replenishment function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The drum unit is designed with multi-functionality, serving both as the image forming component and as the toner replenishment system. The developer container within the drum unit can directly receive toner from the attached toner cartridge, making the drum unit a universal component that performs both development and replenishment functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If a separate toner replenishing device is provided to replenish toner from the toner cartridge to the developer container, then the toner replenishment function is achieved, but the size of the image forming apparatus increases

Engineering Contradiction:

Improvetoner replenishment functionVSAvoidsize of image forming apparatus

Core Design Contradiction:

ProductivityVSVolume of stationary object

Solution Approach 1:

The patent merges the toner replenishment function into the drum unit by integrating the toner cartridge directly with the developer container. The toner cartridge is configured to be attachable to the drum unit, allowing direct replenishment of toner to the developer container without requiring a separate replenishing device, thus reducing the overall size while maintaining the replenishment function.

Inventive Principle:

Principle #5Merging (Combining)

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 configuration suppresses the increase in size of the image forming apparatus and drum unit by integrating toner replenishment directly into the drum unit, enhancing operational efficiency.

Implementation Method 1

The developing unit includes a magnetic roller, a developer container, a first auger and a second auger. The magnetic roller is positioned between the toner cartridge and the photosensitive drum and rotatable about a second axis extending in the second direction. The magnetic roller faces a surface of the photosensitive drum.

Methodology Applied

Scientific EffectMagnetic attraction: Magnetism

Implementation Method 2

The first auger is positioned in the developer container and rotatable about a third axis extending in the second direction. The first auger is configured to circulate the toner and the carrier in the developer container. The second auger is positioned in the developer container and rotatable about a fourth axis extending in the second direction. The second auger is configured to convey the toner and the carrier to the magnetic roller.

Methodology Applied

Scientific EffectMechanical conveyance: Archimedes Screw

Data Source

PatentUS20250013170A1Image forming apparatus capable of suppressing increase in size

Publication Date: 2025.01.09 BROTHER KOGYO KK

AI summary

An image forming apparatus including a housing, a toner cartridge, and a drum unit. The drum unit is movable through the opening between an accommodated position where the drum unit is positioned in the housing and a pulled-out position where the drum unit is pulled out of the housing. The drum unit includes a photosensitive drum and a developing unit. The photosensitive drum is rotatable about a first axis extending in a second direction. The developing unit includes a magnetic roller, a developer container, a first auger and a second auger. The magnetic roller is positioned between the toner cartridge and the photosensitive drum. The magnetic roller faces a surface of the photosensitive drum. The developer container is formed with an inlet allowing the toner to be replenished from the toner cartridge. The first auger is positioned in the developer container. The second auger is positioned in the developer container.