Toner Refill Cartridge Plunger Sensing for Injection Completion

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Solution Overview

Problem

Existing image forming apparatuses face challenges in efficiently refilling toner without requiring the development cartridge to be removed, and there is a need for a system to accurately detect the completion of toner injection during the refilling process.

Innovation Solution

The development cartridge is equipped with a toner refilling portion that allows for toner refill without removal, and a toner refill cartridge with a plunger and toner injection completion signal generator, which includes electrodes or a magnetic substance to detect toner injection completion, ensuring proper refilling and communication with the apparatus.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the development cartridge is removed for toner refilling, then the refilling process can be performed, but the operation complexity and time consumption increase

Engineering Contradiction:

Improveease of refillingVSAvoidtime for cartridge removal and reinstallation

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The invention separates the toner container from the development cartridge, allowing the toner container to be refilled independently while the development cartridge remains installed in the image forming apparatus. This segmentation enables refilling without removing the development cartridge, thus reducing operation time and complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention introduces a refilling port as an intermediary interface between the external refilling device and the toner container. This intermediary allows toner to be injected into the toner container through the development cartridge without removing the cartridge from the apparatus, solving the contradiction between ease of refilling and time loss.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If a simple refilling structure is used, then the device complexity is reduced, but the ability to detect toner injection completion is lost

Engineering Contradiction:

Improverefilling structure complexityVSAvoiddetection of toner injection completion

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The invention replaces complex mechanical detection mechanisms with a simpler magnetic detection system. A magnetic substance is attached to the plunger, and a magnetic sensor detects its position to determine toner injection completion. This substitution reduces device complexity while maintaining accurate detection capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The magnetic substance on the plunger acts as an intermediary that translates the physical position of the plunger into a detectable signal for the magnetic sensor. This intermediary enables accurate detection of toner injection completion without requiring complex mechanical sensors or switches.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the toner container is sealed to prevent contamination, then the reliability is improved, but the ease of refilling is reduced

Engineering Contradiction:

Improvetoner contamination preventionVSAvoidease of toner refilling

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The invention segments the toner container into a sealed main body and a separate refilling port. The refilling port can be opened for toner injection while the rest of the container remains sealed, preventing contamination during normal operation while allowing controlled refilling when needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The refilling port is designed to be opened only when refilling is required, and the toner container is pre-sealed to prevent contamination. This preliminary sealing action maintains reliability during normal use, while the pre-designed refilling port enables easy refilling when needed without compromising the sealed structure.

Inventive Principle:

Principle #10Preliminary action

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

Enables easy and accurate toner refilling without disassembly, ensuring the apparatus recognizes completion of the process and maintains operational efficiency.

Implementation Method 1

a magnetic sensor 15 for detecting the toner injection completion signal

Methodology Applied

Scientific EffectMagnetic field detection: Magnetic Field

Data Source

PatentEP3765916B1Detecting completion of injection of toner of toner refill cartridge

Publication Date: 2025.11.12 HEWLETT PACKARD DEVELOPMENT COMPANY LP

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AI summary

A toner refill cartridge includes a body in which toner is accommodated, a plunger inserted into the body and movably coupled to the body in a longitudinal direction of the body to push the toner out of the body, a toner injection completion signal generator used to detect toner injection completion according to movement of the plunger, and a connection interface located at a tip portion of the body and connectable to an image forming apparatus to transfer information about a toner refill cartridge to the image forming apparatus.