Filter Unit with Planar Airflow Paths for Compact Toner Collection
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Solution Overview
Problem
In small image forming apparatuses, such as desktop printers, it is challenging to secure a location for a filter to collect scattered toner without increasing the apparatus size, as existing filter designs often require more space due to their perpendicular airflow paths.
Innovation Solution
A filter unit with a rectangular parallelepipedic chassis featuring internal ribs that form airflow paths along the bottom and top surfaces, allowing air to pass through the filter from below to above, reducing the thickness of the chassis and preventing size expansion, while the filter is sandwiched by ribs and shield plates to maintain airflow efficiency and prevent clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a filter is mounted in a small image forming apparatus, then scattered toner can be collected, but the apparatus size increases and it becomes difficult to secure a location for the filter
Solution Approach 1:
The airflow path is changed from a conventional perpendicular arrangement to a planar arrangement that extends in the width direction of the chassis. The ribs extend in the width direction to form airflow paths that run parallel to the longitudinal axis, transforming the three-dimensional space utilization and reducing the thickness dimension while maintaining effective filtration area.
Solution Approach 2:
The filter assembly is segmented into multiple ribs extending in the width direction, creating multiple parallel airflow paths. This segmentation allows the filter to be distributed across the width of the chassis rather than requiring a single large space, enabling better space utilization and reduced overall thickness.
2Reliability
If air flows perpendicularly through the filter, then filtration is effective, but the chassis thickness increases
Solution Approach 1:
The airflow direction is changed from perpendicular to the filter surface to parallel to the filter surface, with air entering through gaps between ribs and flowing along the filter media in the width direction. This dimensional change allows effective filtration to occur within a thinner profile by utilizing the width dimension instead of the thickness dimension.
Solution Approach 2:
The filter is divided into multiple segments by ribs that create individual airflow channels. Each rib segment handles a portion of the airflow, allowing the total filtration function to be distributed across multiple thin layers rather than requiring a single thick perpendicular path.
3Stability of the object's composition
If the filter is tightly mounted, then structural stability is improved, but airflow paths are blocked and clogging occurs
Solution Approach 1:
The filter assembly uses multiple ribs with gaps between them, creating a segmented structure that provides both mechanical support and airflow channels. The ribs are spaced to maintain structural integrity while preserving sufficient gaps for air to pass through and reach the filter media without blockage.
Solution Approach 2:
Different regions of the filter assembly have different properties: the ribs provide rigid structural support where needed, while the gaps between ribs provide open airflow paths. The shield plates provide localized support at the ends of the filter while maintaining open gaps at the bottom and top surfaces for air entry and exit.
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
The solution allows for a thinner filter unit that effectively collects scattered toner without increasing the apparatus size, reducing clogging by allowing toner particles to fall under their own weight into airflow paths and maintaining smooth air flow, thus preventing image defects.
Implementation Method 1
a suction portion provided at a front side of the rectangular parallelepipedic chassis to suck air therethrough
Implementation Method 2
provided internally with a filter capable of collecting powder particles
Implementation Method 3
a plurality of first ribs disposed parallel to sidewalls of the chassis to rise from a bottom surface of the chassis toward an interior of the chassis and forming a first airflow path
Implementation Method 4
allowing toner particles to fall under their own weight into airflow paths
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A filter unit (300) includes: a chassis (303) that has a suction portion (301) provided at a front side thereof, has an exhaust portion (302) provided at a rear side thereof, and is provided internally with an upstream filter (331); a plurality of upstream first ribs (323) disposed parallel to sidewalls of the chassis (303) to rise from a bottom surface (322) of the chassis (303) and forming an upstream first airflow path (P11); a plurality of upstream second ribs (313) disposed parallel to the sidewalls of the chassis (303) to rise from a ceiling surface (312) of the chassis (303) and forming an upstream second airflow path (P21); an upstream first shield plate (315) raised from the ceiling surface (312) to cover up a front of the upstream filter (331) while forming an upstream first gap (S11) with the bottom surface (322); and an upstream second shield plate (325) raised from the bottom surface (322) to cover up a rear of the upstream filter (331) while forming an upstream second gap (S21) with the ceiling surface (312).