Toner Density Sensor Diaphragm Segmentation for Accuracy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing toner density sensors face variations in detection accuracy due to displacement of surface-mounted light emitting and receiving elements, which is exacerbated by size reduction challenges in manufacturing diaphragm units that effectively block unwanted light paths.
Innovation Solution
A toner density sensor design featuring a diaphragm unit with upper and lower portions, where the lower portion protrudes from the rear surface to the front surface through a through hole in the substrate, allowing for precise light path narrowing and improved detection accuracy while enabling size reduction of the light emitting and receiving parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If surface-mounted elements are used for light emitting and receiving parts, then ease of manufacture is improved, but mounted position displacement occurs causing variations in detection accuracy
Solution Approach 1:
The light path is divided into multiple segments by introducing diaphragm units at different positions. The first diaphragm unit is positioned near the light emitting part and the second diaphragm unit is positioned near the light receiving part, creating segmented light path control that maintains detection accuracy while using surface-mounted elements.
Solution Approach 2:
Diaphragm units are introduced as intermediary elements between the light emitting part and light receiving part. These diaphragm units act as mediators that regulate and narrow the light path, ensuring that only light from the intended direction reaches the light receiving part, thereby compensating for position displacement of surface-mounted elements.
2Measurement precision
If diaphragm unit is formed to narrow light path for suppressing detection accuracy variations, then detection accuracy is improved, but device size increases making size reduction difficult
Solution Approach 1:
The diaphragm unit is segmented into multiple portions (first diaphragm unit and second diaphragm unit) positioned at different locations. This segmentation allows each diaphragm unit to be smaller in individual size while collectively achieving the light path narrowing function, thus reducing the overall device volume compared to a single large diaphragm unit.
Solution Approach 2:
The light path control is extended from a single-plane diaphragm to a multi-dimensional arrangement with diaphragm units positioned at different depths and locations. The first diaphragm unit is positioned closer to the light emitting part while the second diaphragm unit is positioned closer to the light receiving part, creating a distributed three-dimensional light path regulation system that reduces the footprint of each individual component.
3Object-affected harmful factors
If diaphragm unit lower portion protrudes significantly from substrate front surface, then light path blocking effectiveness is improved, but manufacturing complexity and protrusion requirements increase
Solution Approach 1:
The diaphragm unit is divided into multiple portions with different protrusion heights from the substrate front surface. The first diaphragm unit portion has a first protrusion height while the second diaphragm unit portion has a second protrusion height, allowing each segment to provide appropriate light blocking at its specific location without requiring all portions to protrude significantly, thus reducing overall manufacturing complexity.
Solution Approach 2:
Different portions of the diaphragm unit are given different local characteristics in terms of protrusion height. The first diaphragm unit portion protrudes to a extent suitable for blocking light near the light emitting part, while the second diaphragm unit portion protrudes to a different extent suitable for blocking light near the light receiving part. This local differentiation optimizes light blocking effectiveness at each location while minimizing the maximum protrusion height required, thereby reducing manufacturing complexity.
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 effectively suppresses variations in detection accuracy and allows for size reduction of the toner density sensor by ensuring reliable light path regulation, even with smaller elements, and enhances manufacturing feasibility by minimizing protrusion requirements.
Implementation Method 1
a light emitting part that applies light
Implementation Method 2
light receiving parts 103, 104 that receive light having been applied from the light emitting part 102 and reflected at a detection target, and an amplification unit that amplifies detection voltages of the light receiving parts 103, 104
Data Source
AI summary
A toner density sensor comprising: a light emitting element that emits light; a light receiving element that receives reflected light emitted from the light emitting part and reflected at a detection target; a light path for passage of emitted and reflected light formed along the front surface of a printed substrate on which the light emitting element and the light receiving element are surface-mounted; and a diaphragm unit that is formed at and partially narrows this light path, wherein the diaphragm unit is divided into two portions, a diaphragm unit upper-portion and a diaphragm unit lower-portion, and these are disposed in an upper case covering the front surface of the printed substrate and in a lower case covering the rear surface of the printed substrate. In the printed substrate, a through hole is formed for protrusion of the diaphragm unit lower portion from the rear surface to the front surface.