Optical Sensor Oblique Hole Design for Toner Detection
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Solution Overview
Problem
Optical sensors used in image forming apparatuses face challenges in reducing light interference from through holes and maintaining precise distances between light-emitting, light-receptive elements, and lenses, leading to reduced accuracy and precision in measuring toner image positions and densities.
Innovation Solution
The optical sensor configuration includes a plate-shaped substrate with strategically positioned holes and light-shielding walls, where light-receptive elements are fixed to the back surface, and a holder system with hooks and lugs to ensure accurate positioning and minimize light interference, allowing for improved light transmission and precise assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the light-receptive element is located on the back surface of the substrate, then the thickness of the optical sensor is reduced, but the quantity of light reaching the light-receptive element is reduced due to interruption by the edge of the through hole
Solution Approach 1:
The hole is designed to extend in an oblique direction rather than perpendicular to the substrate surfaces. This angular orientation allows the hole to connect the front and back surfaces while avoiding the edge interruption problem, enabling the light-receptive element to be positioned on the back surface without sacrificing light quantity.
Solution Approach 2:
The hole's orientation is specifically tailored to the local geometric requirements. By extending at an angle from the front surface to the back surface, the hole creates an optimal light path that bypasses the edge interruption issue while maintaining the thin profile of the optical sensor.
2Quantity of substance
If the hole extends from the light-receptive element position toward the light-emitting element position, then light interruption by the hole edge is reduced, but the positioning precision of the light path may be compromised
Solution Approach 1:
The hole's oblique orientation is specifically designed to match the spatial relationship between the light-emitting element and light-receptive element. This localized geometric configuration ensures that light travels directly from the source to the detector without edge interruption, while the precise angular design maintains accurate positioning.
Solution Approach 2:
The obliquely extending hole acts as an intermediary light path that connects the light-emitting element and light-receptive element. This intermediate structure facilitates direct light transmission while accommodating the spatial arrangement of components, thereby maintaining positioning precision.
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 reduces light interference, enhances the accuracy and precision of light readouts, and facilitates easier assembly by ensuring precise alignment of light-emitting and light-receptive elements, thereby improving the measurement of toner image positions and densities.
Implementation Method 1
a light-emitting element 120 that emits light L
Implementation Method 2
reflected light emitted from the light-emitting element 120, reflected off the sensing object 73 and traveling into the first hole 111
Data Source
AI summary
An optical sensor configured to detect a sensing object includes a plate-shaped substrate, a light-emitting element, and a first light-receptive element. The plate-shaped substrate has a front surface, a back surface and a first hole piercing through the front surface and the back surface. The light-emitting element emits light and is fixed to the substrate. The first light-receptive element receives reflected light emitted from the light-emitting element, reflected off the sensing object and traveling into the first hole. The first light-receptive element is fixed to the back surface of the substrate. The first hole extends from a position at which the first light-receptive element is fixed toward a position at which the light-emitting element is fixed.