Toner Container Level Control for Leakage Prevention

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Solution Overview

Problem

Image forming apparatuses face the challenge of toner leakage due to waste toner accumulation, leading to malfunction when the toner container reaches maximum storage level, requiring a method to delay this occurrence without increasing user strain.

Innovation Solution

Incorporating a control unit that suppresses waste toner generation by adjusting the number of printed sheets and reducing the area or number of tones in density patterns when the toner level reaches a predetermined storage level lower than the maximum, thereby delaying the maximum storage level without straining the user.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the image forming operation is stopped when waste toner reaches maximum storage level, then toner leakage is prevented, but productivity is reduced

Engineering Contradiction:

Improveprevention of toner leakageVSAvoidimage forming operation continuity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system performs preliminary action by suppressing waste toner generation before the container reaches maximum storage level. When the waste toner level reaches a predetermined threshold, the control unit suppresses formation of density patterns and other processes that generate waste toner, thereby extending the operational life of the toner container without risking overflow.

Inventive Principle:

Principle #10Preliminary action

2Measurement precision

If density patterns are formed for measurement, then transfer image density can be adjusted, but waste toner is generated

Engineering Contradiction:

Improvetransfer image density measurementVSAvoidwaste toner generation

Core Design Contradiction:

Measurement precisionVSLoss of substance

Solution Approach 1:

The system changes operational parameters by suppressing density pattern formation when waste toner reaches the predetermined storage level. The control unit dynamically adjusts whether density measurement patterns are formed based on the current waste toner level, thereby controlling waste toner generation while maintaining measurement capability when needed.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If the predetermined storage level is set close to maximum storage level, then productivity is maintained, but toner leakage risk increases

Engineering Contradiction:

Improveimage forming operation continuityVSAvoidtoner containment safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system applies beforehand cushioning by setting a predetermined storage level that provides a safety buffer below the maximum storage level. This cushion zone allows the system to suppress waste toner generation proactively before the container reaches its maximum capacity, preventing toner leakage while maintaining operational productivity.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS7551863B2Image forming apparatus having a cleaning unit for collecting waste toner

Publication Date: 2009.06.23 BROTHER KOGYO KK

AI summary

An image forming apparatus includes an image carrier, a cleaning unit that collects a waste toner that remains on the image carrier, a toner container that stores the waste toner collected by the cleaning unit, a determination unit that determines whether the waste toner stored in the toner container reaches a predetermined storage level that is lower than a maximum storage level of the toner container, and a control unit that executes a control of suppressing generation of the waste toner when the determination unit determines that the waste toner has reached the predetermined storage level.