Separable Toner and Drum Cartridge for Cost Reduction
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Solution Overview
Problem
In existing image forming apparatuses, the need to replace the entire cartridge, including a photosensitive drum, when toner levels are low leads to unnecessary costs and inefficiencies, as the drum itself may still be functional.
Innovation Solution
The design allows for the separation of the drum cartridge and toner cartridge, enabling individual replacement of each component, with a cleaning member positioned between the photosensitive drum and the fixing device, and a toner cartridge with movable shutters and levers for efficient toner and waste toner management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire cartridge including the photosensitive drum is replaced when toner is depleted, then the toner supply function is restored, but unnecessary cost is incurred and resource waste occurs since the drum may still be functional
Solution Approach 1:
The cartridge is divided into two separable components: a drum cartridge containing the photosensitive drum and a toner cartridge containing the toner supply. This segmentation allows the toner cartridge to be replaced independently when toner is depleted, while the drum cartridge can continue to be used, thereby avoiding unnecessary resource waste while ensuring reliable toner supply.
Solution Approach 2:
The toner supply system is extracted from the integrated cartridge and separated into a standalone toner cartridge that can be individually replaced. This extraction enables users to replace only the depleted toner component without discarding the still-functional drum, reducing resource waste while maintaining reliable toner availability.
2Reliability
If the entire cartridge including the photosensitive drum is replaced when toner is depleted, then the image forming function is restored, but replacement cost increases unnecessarily
Solution Approach 1:
The cartridge system is segmented into a drum cartridge and a toner cartridge, allowing selective replacement of only the toner cartridge when needed. This reduces replacement costs by avoiding unnecessary replacement of the drum cartridge, while ensuring image forming reliability is restored through timely toner replacement.
Solution Approach 2:
The toner supply mechanism is extracted as a separate replaceable unit, enabling cost-effective replacement of only the consumable toner component while retaining the reusable drum cartridge, thus lowering overall replacement costs while maintaining reliable image forming capability.
3Reliability
If the cleaning member is located between the photosensitive drum and the fixing device, then waste toner removal is effective, but the structure becomes more complex
Solution Approach 1:
The cleaning member is integrated into the drum cartridge assembly and positioned between the photosensitive drum and the fixing device. This merging of the cleaning function into the existing cartridge structure achieves effective waste toner removal without significantly increasing overall system complexity, as the cleaning member utilizes the existing spatial relationship between components.
Data Source
AI summary
An image forming apparatus includes an apparatus main body, a drawer, a drum cartridge, an exposure device, a fixing device, and a toner cartridge. The drum cartridge includes a photosensitive drum, a cleaning member, a developing device, a waste toner conveying pipe, and a frame. The toner cartridge includes a toner container and a waste toner container. The cleaning member is located between the photosensitive drum and the fixing device in a vertical direction in the state where the drum cartridge is mounted to the drawer and the drawer is located at an inner position. The drum cartridge is capable of being mounted to the drawer. The toner cartridge is attachable to and detachable from the drum cartridge.