Blow-Molded Toner Bottle with Integral Drive Tabs

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Solution Overview

Problem

Existing electrophotography systems face challenges with high manufacturing costs and contamination due to the use of two separate plastic parts in toner bottles, where an injection-molded cap is needed for the drive mechanism, and there is no assurance that only the correct toner type is used, leading to potential contamination.

Innovation Solution

A 100% blow-molded toner bottle design with integral tabs and a drive dog featuring shaped slots and lead-in chamfers, allowing for a one-piece construction that ensures only compatible bottles are used, preventing contamination and reducing costs by eliminating the need for an injection-molded cap.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If an injection-molded cap is used to provide the drive mechanism for the bottle, then the bottle can be driven and augmented, but the manufacturing cost increases significantly

Engineering Contradiction:

Improvedrive mechanism functionalityVSAvoidmanufacturing cost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The patent merges the drive interface features directly into the blow-molded bottle body, eliminating the need for a separate injection-molded cap. The bottle includes integrated drive interface features such as drive tabs or drive slots that directly engage with the drive dog, combining the container and drive mechanism into a single blow-molded component, thereby reducing part count and manufacturing cost while maintaining drive functionality

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The blow-molded bottle is designed to serve multiple functions: it acts as both the toner container and the driven element. The bottle body itself incorporates the drive interface features, making it a multi-functional component that eliminates the need for a separate cap structure, thereby simplifying manufacturing while preserving the drive and auger functions

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If a universal drive interface is used, then any bottle can be driven, but the system cannot prevent contamination from incorrect toner types

Engineering Contradiction:

Improvebottle compatibilityVSAvoidcontamination from incorrect toner

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent employs asymmetric drive interface features on the bottle that must match corresponding asymmetric features on the drive dog. The bottle includes specific tab configurations or slot orientations that only align with the drive dog when the correct bottle type is installed, creating a mechanical key-lock system that prevents incorrect bottles from being driven and thus prevents contamination

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The drive interface is designed with preliminary preventing features that stop incorrect bottles from being installed or driven in the first place. The asymmetric geometry of the drive tabs and slots creates a mechanical barrier that physically prevents mismatched bottles from engaging with the drive mechanism, thereby preemptively avoiding contamination before it can occur

Inventive Principle:

Principle #9Preliminary anti-action

3Ease of operation

If two separate plastic parts are assembled together, then the drive mechanism can be provided, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improvedrive functionalityVSAvoidnumber of parts

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent combines the bottle body and cap functions into a single integrated blow-molded component. The bottle includes integrated drive interface features such as drive tabs or slots that are formed directly during the blow-molding process, eliminating the need for a separate injection-molded cap and reducing the assembly to a single part, thereby simplifying the device structure while maintaining drive functionality

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single blow-molded bottle serves multiple functions simultaneously: it acts as the toner reservoir, incorporates the drive interface for mechanical engagement, and includes the auger drive features. This multi-functional design eliminates the need for separate cap components, reducing part count and assembly complexity while preserving all necessary operational functions

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS8261426B2Method of constructing a toner dispensing unit

Publication Date: 2012.09.11 XEROX CORP

AI summary

This is a toner-dispensing unit using a blow-molded, one-piece toner bottle with integral tabs. The tabs are uniquely designed so that they can only be used with specific marking machines. The tabs fit into mating slots in a drive dog so that installation, while usually a blind installation of bottles, is easily accomplished. The one-piece, blow-molded bottle with integral tabs used with mating slots in a drive dog provides an improvement over prior used toner-dispensing units.