Waste Toner Container Backflow Prevention for Accurate Level Detection

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Solution Overview

Problem

The existing waste toner-storing containers in image forming apparatuses face issues with accurate detection of fullness after the container is shaken or turned upside down, leading to potential malfunctions due to incorrect sensing of toner levels, which can cause overflow and clog the toner-discharging pipes.

Innovation Solution

The implementation of a waste toner-storing container with a backflow-preventing member and a second storing chamber that prevents toner from flowing back, ensuring accurate detection of fullness even when the container's posture changes, thereby preventing erroneous detection and malfunctions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the waste toner-storing container is shaken or turned upside down to empty it, then the toner can be discharged more completely, but the toner level detection becomes inaccurate leading to potential overflow

Engineering Contradiction:

Improvetoner discharge completenessVSAvoidtoner level detection accuracy

Core Design Contradiction:

Quantity of substanceVSMeasurement precision

Solution Approach 1:

The waste toner container is divided into two separate chambers: a first storing chamber for receiving waste toner and a second storing chamber for storing overflowed toner. This segmentation allows the system to handle both complete discharge and accurate detection independently, resolving the contradiction between emptying effectiveness and detection accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A backflow-preventing member is introduced as an intermediary component between the two chambers. This member prevents toner from flowing back from the second chamber to the first chamber after shaking, ensuring that the toner level in the first chamber remains stable for accurate sensor detection while still allowing complete discharge during shaking operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If the waste toner-storing container is designed with a single chamber, then the structure is simple, but toner overflow can occur when the container is shaken or tilted

Engineering Contradiction:

Improvecontainer structure simplicityVSAvoidtoner overflow prevention

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The container is segmented into two chambers with distinct functions: the first chamber receives waste toner during normal operation, while the second chamber captures overflow during shaking or tilting. This segmentation maintains structural simplicity while reliably preventing toner overflow onto external components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of viewing toner overflow during shaking as a harmful effect to be eliminated, the design converts it into a beneficial feature by directing the overflow into the second chamber. This allows the container to be shaken for complete discharge without risking external contamination, transforming a potential problem into a functional advantage.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of operation

If the waste toner-storing container allows free flow of toner, then toner can move freely during shaking, but the toner level sensor may give erroneous readings after reattachment

Engineering Contradiction:

Improvecontainer shaking effectivenessVSAvoidsensor detection accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The backflow-preventing member acts as an intermediary that controls toner flow between chambers. During shaking, toner can freely move into the second chamber, but the backflow-preventing member then prevents it from returning to the first chamber, ensuring stable toner levels for accurate sensor readings after the container is reattached to the image forming apparatus.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution ensures reliable detection of toner fullness, preventing malfunctions and toner overflow, and maintaining the integrity of the toner-discharging process by maintaining accurate toner levels within the container.

Implementation Method 1

The backflow-preventing member prevents waste toner stored in the second storing space from moving into the first storing chamber

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS10474089B2Waste toner-storing container and image forming apparatus

Publication Date: 2019.11.12 TOSHIBA TEC KK

AI summary

In accordance with an embodiment, a waste toner-storing container includes a container main body and a backflow-preventing member. A first storing chamber of the container main body includes a first storing space capable of storing an amount of waste toner discharged from a main body of an image forming apparatus, which is below a predetermined threshold. A second storing chamber of the container main body includes a second storing space that stores waste toner overflowing from the first storing space and discharged from the first storing chamber if the amount of waste toner exceeds the predetermined threshold. The backflow-preventing member prevents waste toner stored in the second storing space from moving into the first storing chamber.