Toner Sensor Module Transmissive Density Measurement
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Solution Overview
Problem
Conventional reflective densitometry systems in toner printers are unable to accurately measure unfused toner amounts, leading to unreliable process control and increased printer complexity and cost, as they struggle with light reflection from unfused toner particles and the masking effects caused by toner on the receiver surface.
Innovation Solution
A toner sensor module with a first light source and sensor positioned to illuminate and sense light from unfused toner particles on a plane normal to the target area, directing reflected light into the sensor to enhance signal-to-noise ratio and allow for accurate measurement of unfused toner amounts before fusing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional reflective densitometry is used to measure unfused toner, then the system can provide process control feedback, but the measurement precision is poor due to light reflection from unfused toner particles and masking effects
Solution Approach 1:
The patent changes the measurement parameter from reflective density to transmissive density. By measuring the density of light transmitted through unfused toner particles rather than reflected from them, the system achieves accurate measurement of unfused toner amounts. This parameter change eliminates the masking effects and light reflection issues that plague conventional reflective densitometry.
2Extent of automation
If in-line densitometers are installed in toner printers, then process control capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent makes the densitometer serve multiple functions: it measures both fused toner (via reflective density) and unfused toner (via transmissive density) using the same optical assembly. This multi-functionality eliminates the need for separate measurement systems, thereby reducing device complexity and cost while maintaining comprehensive process control capability.
Solution Approach 2:
The patent uses the existing in-line densitometer infrastructure and creates a new measurement mode (transmissive) rather than installing entirely new sensing systems. This approach leverages existing hardware resources and achieves additional functionality with minimal added complexity.
3Measurement precision
If reflective density measurement is used, then the system can measure fused toner, but it cannot accurately determine clear toner fusion amounts
Solution Approach 1:
The patent introduces transmissive density measurement as a complementary parameter to reflective density measurement. Clear toner, which is transparent to light, affects transmissive density but not reflective density. By measuring light transmission through the toner layer, the system can accurately determine clear toner amounts that would be invisible to reflective measurement alone.
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 reliable, real-time measurement of unfused toner amounts, reducing printer complexity and cost by providing accurate process control signals during printing, allowing for adjustments to be made before completing a print, thereby improving print consistency and reducing waste.
Implementation Method 1
illuminate a target area from a first side a plane that is normal to the target area so that illuminated portions of any toner particles at the target area direct a reflected portion of the first light into the first side
Data Source
AI summary
Toner sensor modules are provided. In one aspect, a toner sensor module has a first light source emitting a first light, a first light sensor that generates a sensed light signal that is indicative of a sensed light, and a frame. The frame positions the light source to illuminate a target area from a first side a plane that is normal to the target area so that illuminated portions of any toner particles at the target area direct a reflected a portion of the first light into the first side and positioning the first light sensor on the first side of the plane to which toner particles at the target area direct the reflected portion of the first light.