Toner cartridge having an expandable toner agitator

A toner cartridge for an electrophotographic image forming device according to one example embodiment includes a housing having a reservoir for storing toner. A rotatable drive shaft is positioned within the reservoir. A partition is mounted on the drive shaft and axially movable along the drive shaft when the drive shaft rotates. The partition divides the reservoir into a first compartment for storing fresh toner and a second compartment for storing waste toner. An expandable agitator is positioned within the second compartment and rotatable with the drive shaft. When the drive shaft rotates and the partition moves along the drive shaft expanding a volume of the second compartment, the agitator expands along a length of the drive shaft and rotates with the drive shaft for agitating waste toner in the second compartment.

CROSS REFERENCES TO RELATED APPLICATIONS

BACKGROUND

1. Field of the Disclosure

The present disclosure relates generally to electrophotographic imaging devices such as printers or multifunction devices having printing capability, and more particularly to a toner cartridge having an expandable toner agitator.

2. Description of the Related Art

During the electrophotographic printing process, an electrically charged rotating photoconductive drum is selectively exposed to a laser beam. The areas of the photoconductive drum exposed to the laser beam are discharged creating an electrostatic latent image of a page to be printed on the photoconductive drum. Toner particles are then electrostatically picked up by the latent image on the photoconductive drum creating a toned image on the photoconductive drum. The toned image is transferred to the print media (e.g., paper) either directly by the photoconductive drum in a one-step transfer system or indirectly by an intermediate transfer member in a two-step transfer system. The toner is then fused to the media using heat and pressure to complete the print.

However, not all of the toner picked up by the photoconductive drum is transferred to the print media or intermediate transfer member due to inefficiencies in the image transfer process. Residual toner left on the photoconductive drum after the photoconductive drum has contacted the print media or intermediate transfer member must be removed before the next image is formed in order to avoid contamination of the next image. For this purpose, a cleaner blade or a cleaner brush is placed in contact with the photoconductive drum (and, in a two-step transfer system, the intermediate transfer member) to wipe the residual toner from its surface. The residual toner removed by the cleaner blade or cleaner brush is then stored in a waste toner container. The size of the waste toner container is preferably minimized in order to reduce the overall size of the image forming device.

The image forming device's toner supply is typically stored in one or more toner cartridges that must be replaced periodically to continue to provide toner to the image forming device for printing. In order to ensure optimized performance, it is desirable to communicate conditions of the toner cartridge to the image forming device for proper operation.

SUMMARY

A toner cartridge for an electrophotographic image forming device according to one example embodiment includes a housing having a reservoir for storing toner. A rotatable drive shaft is positioned within the reservoir. A partition is mounted on the drive shaft and axially movable along the drive shaft when the drive shaft rotates. The partition divides the reservoir into a first compartment for storing fresh toner and a second compartment for storing waste toner. An expandable agitator is positioned within the second compartment and rotatable with the drive shaft. When the drive shaft rotates and the partition moves along the drive shaft expanding a volume of the second compartment, the agitator expands along a length of the drive shaft and rotates with the drive shaft for agitating waste toner in the second compartment.

A toner cartridge for an electrophotographic image forming device according to another example embodiment includes a housing having opposed first and second end walls and an elongated body therebetween defining a reservoir for storing toner. A rotatable drive shaft is positioned within the reservoir. A partition is mounted on the drive shaft and axially movable along the drive shaft when the drive shaft rotates. The partition divides the reservoir into a first compartment for storing fresh toner and a second compartment for storing waste toner. An expandable agitator is positioned within the second compartment and rotatable with the drive shaft for agitating waste toner in the second compartment. The agitator has a first end coupled to the drive shaft near the first end wall of the housing and a second end coupled to the partition. When the drive shaft rotates and the partition moves along the drive shaft toward the second end wall of the housing from a first axial position to a second axial position along the drive shaft, the agitator rotates with the drive shaft and expands from a collapsed state to an expanded state.

A toner cartridge for an electrophotographic image forming device according to another example embodiment includes a housing having a reservoir for storing toner. A rotatable drive shaft is positioned within the reservoir. A movable partition divides the reservoir into a first compartment for storing fresh toner and a second compartment for storing waste toner. An expandable agitator is positioned within the second compartment and rotatable with the drive shaft for agitating waste toner in the second compartment. The agitator is coupled to the partition such that when the partition moves along a length of the drive shaft in a manner that expands a volume of the second compartment, the agitator expands along a length of the drive shaft.

DETAILED DESCRIPTION

In the following description, reference is made to the accompanying drawings where like numerals represent like elements. The embodiments are described in sufficient detail to enable those skilled in the art to practice the present disclosure. It is to be understood that other embodiments may be utilized and that process, electrical and mechanical changes, etc., may be made without departing from the scope of the present disclosure. Examples merely typify possible variations. Portions and features of some embodiments may be included in or substituted for those of others. The following description, therefore, is not to be taken in a limiting sense and the scope of the present disclosure is defined only by the appended claims and their equivalents.

Referring now to the drawings and particularly toFIG. 1, there is shown a diagrammatic depiction of an imaging system20according to one example embodiment. As shown, imaging system20may include an imaging apparatus22and a computer24. Imaging apparatus22communicates with computer24via a communications link26. As used herein, the term “communications link” is used to generally refer to any structure that facilitates electronic communication between multiple components, and may operate using wired or wireless technology and may include communications over the Internet.

In the embodiment shown inFIG. 1, imaging apparatus22is shown as a multifunction machine that includes a controller28, a print engine30, a laser scan unit (LSU)31, an imaging unit32, a toner cartridge35, a waste toner transfer system36, a user interface37, a media feed system38, a media input tray40and a scanner system41. Imaging apparatus22may communicate with computer24via a standard communication protocol, such as, for example, universal serial bus (USB), Ethernet or IEEE 802.xx. A multifunction machine is also sometimes referred to in the art as an all-in-one (AIO) unit. Those skilled in the art will recognize that imaging apparatus22may be, for example, an electrophotographic printer/copier including an integrated scanner system41or a standalone printer.

Controller28includes a processor unit and associated memory29and may be formed as one or more Application Specific Integrated Circuits (ASICs). Memory29may be any volatile or non-volatile memory or combinations thereof such as, for example, random access memory (RAM), read only memory (ROM), flash memory, and/or non-volatile RAM (NVRAM). Alternatively, memory29may be in the form of a separate electronic memory (e.g., RAM, ROM, and/or NVRAM), a hard drive, a CD or DVD drive, or any memory device convenient for use with controller28. Controller28may be, for example, a combined printer and scanner controller.

In the example embodiment illustrated, controller28communicates with print engine30via a communications link50. Controller28communicates with imaging unit32and processing circuitry44thereon via a communications link51. Controller28communicates with toner cartridge35and processing circuitry45therein via a communications link52. Controller28communicates with waste toner transfer system36via communications link53. Controller28communicates with media feed system38via a communications link54. Controller28communicates with scanner system41via a communications link55. User interface37is communicatively coupled to controller28via a communications link56. Processing circuits44, may provide authentication functions, safety and operational interlocks, operating parameters and usage information related to imaging unit32and toner cartridge35, respectively. Each of processing circuitry44,45includes a processor unit and associated electronic memory. As discussed above, the processor may include one or more integrated circuits in the form of a microprocessor or central processing unit and may be formed as one or more Application-specific integrated circuits (ASICs). The memory may be any volatile or non-volatile memory or combination thereof or any memory device convenient for use with processing circuitry44,45. Controller28serves to process print data and to operate print engine30during printing, as well as to operate scanner system41and process data obtained via scanner system41.

Computer24, which is optional, may be, for example, a personal computer, network server, tablet computer, smartphone or other hand-held electronic device, including memory60, such as volatile and/or non-volatile memory, an input device62, such as a keyboard, and a display, such as a monitor64. Computer24further includes a processor, input/output (I/O) interfaces, and may include at least one mass data storage device, such as a hard drive, a CD-ROM and/or a DVD unit (not shown).

Computer24includes in its memory a software program including program instructions that function as an imaging driver66, e.g., printer/scanner driver software, for imaging apparatus22. Imaging driver66is in communication with controller28of imaging apparatus22via communications link26. Imaging driver66facilitates communication between imaging apparatus22and computer24. One aspect of imaging driver66may be, for example, to provide formatted print data to imaging apparatus22, and more particularly, to print engine30, to print an image. Another aspect of imaging driver66may be, for example, to facilitate collection of scanned data.

In some circumstances, it may be desirable to operate imaging apparatus22in a standalone mode. In the standalone mode, imaging apparatus22is capable of functioning without computer24. Accordingly, all or a portion of imaging driver66, or a similar driver, may be located in controller28of imaging apparatus22so as to accommodate printing and scanning functionality when operating in the standalone mode.

Print engine30includes laser scan unit31, toner cartridge35, imaging unit32, and a fuser39, all mounted within imaging apparatus22. The imaging unit32is removably mounted in imaging apparatus22and includes a developer unit34that houses a toner sump and a toner development system. In one embodiment, the toner development system utilizes what is commonly referred to as a single component development system. In this embodiment, the toner development system includes a toner adder roll that provides toner from the toner sump to a developer roll. A doctor blade provides a metered uniform layer of toner on the surface of the developer roll. In another embodiment, the toner development system utilizes what is commonly referred to as a dual component development system. In this embodiment, toner in the toner sump of developer unit34is mixed with magnetic carrier beads. The magnetic carrier beads may be coated with a polymeric film to provide triboelectric properties to attract toner to the carrier beads as the toner and the magnetic carrier beads are mixed in the toner sump. In this embodiment, developer unit34includes a magnetic roll that attracts the magnetic carrier beads having toner thereon to the magnetic roll through the use of magnetic fields. Imaging unit32also includes a cleaner unit33that houses a photoconductive drum and a waste toner removal system.

In one embodiment, the cleaner unit33and developer unit34are assembled together and installed onto a frame of the imaging unit32. The toner cartridge35is then installed on or in proximity with the frame in a mating relation with the developer unit34. Laser scan unit31creates a latent image on the photoconductive drum in the cleaner unit33. Toner is transferred from the toner sump in developer unit34to the latent image on the photoconductive drum by the developer roll (in the case of a single component development system) or by the magnetic roll (in the case of a dual component development system) to create a toned image. The toned image is subsequently transferred to a media sheet from media input tray40for printing. Toner may be transferred directly to the media sheet by the photoconductive drum in a one-step transfer system or by an intermediate transfer member that receives the toner from the photoconductive drum in a two-step transfer system. The toner image is bonded to the media sheet in the fuser39and then sent to an output location or to one or more finishing options such as a duplexer, a stapler or hole punch. Toner remnants are removed from the photoconductive drum (and, in the case of a two-step transfer system, the intermediate transfer member) by the waste toner removal system and are transported back into the toner cartridge35by the waste toner transfer system36as discussed in greater detail below.

Controller28oversees the functioning of the imaging apparatus22including, imaging unit32, LSU31, waste toner transfer system36, user interface37and the movement of the media along media path(s) within imaging apparatus22. Toner cartridge35and/or imaging unit32may also contain its own associated memory as discussed above.

FIG. 2illustrates a schematic illustration of imaging unit32and toner cartridge with waste toner transfer system36according to one example embodiment. In the example embodiment illustrated, developer unit34utilizes a single component development system. In this embodiment, developer unit34includes a toner adder roll82, a doctor blade83, a developer roll84and a toner sump85. An exit port114on the toner cartridge35communicates, either directly or through an intermediate channel, with an inlet port on the developer unit34allowing toner to be periodically transferred from the toner cartridge35to resupply the toner sump85in the developer unit34. The toner adder roll82coats the developer roll84with toner while electrostatically charging the toner particles. As the toner is placed on the developer roll84, the doctor blade83evens the toner to a predetermined thickness. A charging roll86forms a nip with photoconductive drum80and charges the surface of photoconductive drum80to a specified voltage. A laser beam LB from laser scan unit31is directed to the surface of photoconductive drum80and discharges those areas it contacts to form a latent image. The developer roll84, which also forms a nip with photoconductive drum80, then transfers toner to photoconductive drum80to form a toner image. The toner is attracted to the areas of the surface of photoconductive drum80discharged by the laser beam. The cleaner unit33then removes any remaining particles of toner from photoconductive drum80after the toner image is transferred to either the media or an intermediate transfer mechanism. Cleaner unit33includes a storage volume91for collecting waste toner. A cleaner roll or blade92abuts photoconductive drum80(and, in the case of a two-step transfer system, the intermediate transfer member) to remove waste toner from the surface thereof. Waste toner removed by cleaner blade92collects within the storage volume91.

In one example embodiment, waste toner transfer system36includes a waste toner transport mechanism95disposed between cleaner unit33and toner cartridge35for transporting waste toner collected within storage volume91back into toner cartridge35. In the example shown, waste toner transport mechanism95includes a waste tube97having a first end97-1in fluid communication with storage volume91via a waste toner outlet87of cleaner unit33and a second end97-2which fluidly communicates with a waste toner inlet port116of toner cartridge35. In one example embodiment, waste tube97defines an auger path between the cleaner unit33and toner cartridge35. For example, a spiral screw-like auger or auger wire may be provided along the length of waste tube97and driven by a motor (not shown) to transport waste toner from waste toner storage volume91to toner cartridge35.

Referring now toFIG. 3, toner cartridge35is shown according to one example embodiment. Toner cartridge35includes a housing100having a body102with first and second ends104,106. Body102may be termed “tubular” or “elongate” and may have various shapes other than that shown in the example illustration. Enclosing each of ends104,106are first and second end walls108,110, respectively forming a toner reservoir112for containing toner. Exit port114is shown positioned on a lower portion of body102near one of the ends, end104as illustrated. Exit port114is in fluid communication with toner reservoir112to allow toner to be delivered from the toner reservoir112to the toner sump85of developer unit34. Waste toner inlet port116is shown provided on an upper portion of body102near end wall110opposite exit port114. Waste toner inlet port116is also in fluid communication with toner reservoir112to allow waste toner to be delivered by waste toner transfer system36from the cleaner unit33to toner cartridge35and into toner reservoir112. A shutter (not shown) may be provided on each of exit port114and waste toner inlet port116that is biased closed to provide added sealing of the exit port114and waste toner inlet port116when toner cartridge35is not installed in imaging apparatus22.

Aligned openings118-1,118-2are provided in end walls108,110. A drive shaft120is positioned within toner reservoir112and extends along the length of the body102with first and second ends121,122thereof extending into aligned openings118-1,118-2in end walls108,110. A drive coupler (not shown) is operatively connected to drive shaft120and exposed on the exterior of housing100such that when toner cartridge35is inserted into imaging apparatus22, the drive coupler engages with a drive mechanism (not shown) in imaging apparatus22that provides rotational force to the drive coupler and, in turn, drive shaft120. The size and configuration of the drive coupler is a matter of design choice and may include a gear or gear train or a coupler such as an Oldham coupler as is known in the art. The drive mechanism in imaging apparatus22may be provided with an encoder (not shown) that allows controller28to monitor the amount of rotation, angular position and speed of drive shaft120.

Drive shaft120has a threaded portion123and an unthreaded portion124that meet at a junction125. In one example embodiment, the diameter of unthreaded portion124is less than or equal to a root diameter of the threaded portion123. In one example embodiment, unthreaded portion124has a length that is greater than a length of threaded portion123. In general, the length of threaded portion123may depend upon how much waste toner is to be collected within toner cartridge35, and/or may correspond to a portion of the longitudinal volume of toner reservoir112for storing waste toner. In one example, threaded portion123has a length that is approximately one-third of the length of drive shaft120within reservoir112. A paddle assembly200is coupled to the drive shaft120along the unthreaded portion124and rotates with drive shaft120to move toner towards exit port114. Toner cartridge35periodically performs a toner addition cycle wherein controller28rotates drive shaft120a predetermined amount in order to rotate paddle assembly200to deliver toner from toner cartridge35to toner sump85of developer unit34when the amount of toner in the toner sump85falls below a threshold. Mounted on the threaded portion123of drive shaft120is a partition300that divides the toner reservoir112into a first toner compartment127for storing fresh toner and a second toner compartment129for storing waste toner. First toner compartment127is in fluid communication with exit port114to allow fresh toner to be supplied to developer unit34. Depending on the axial location of partition300along threaded portion123, waste toner inlet port116may fluidly communicate with the first toner compartment127or second toner compartment129. InFIG. 3, partition300is positioned such that waste toner inlet port116is in fluid communication with second toner compartment129.

Partition300includes a front surface302, a rear surface304and an edge surface306interconnecting the front and rear surfaces302,304. Based on design choice, partition300may be a solid or hollow structure. The front surface302and rear surface304of partition300may be generally smooth and planar and may be generally orthogonal to the axis of rotation of drive shaft120. One of skill in the art will recognize that other shapes, including non-planar, angled or curvilinear shapes, may be used for the front surface302and rear surface304and that the shapes of the front surface302and rear surface304can be different from each other. The edge surface306or outer perimeter of partition300is shaped to closely conform to the cross-sectional shape of toner reservoir112in body102while still being able to travel within toner reservoir112in order to minimize toner leakage around partition300.

In accordance with example embodiments of the present disclosure, partition300is configured to travel along the threaded portion123of the drive shaft120when the drive shaft120rotates. Axial movement of partition300changes the volume of at least one of the first and second toner compartments127,129. For example, in the embodiment illustrated, when drive shaft120rotates in an operative rotational direction, partition300moves axially toward junction125and away from end106decreasing the volume of the first toner compartment127and increasing the volume of the second toner compartment129. Axial movement of partition300towards junction125may also aid in pushing toner within the first toner compartment127toward the exit port114. Conversely, when drive shaft120rotates in a reverse direction opposite the operative rotational direction, partition300moves axially away from junction125and toward end106increasing the volume of the first toner compartment127and decreasing the volume of the second toner compartment129.

Drive shaft120passes through an opening308in partition300. In order to allow partition300to move axially along the threaded portion123of drive shaft120, in the example embodiment illustrated, opening308has a threaded inner circumferential surface forming a threaded hole308that matably couples to the threaded portion123of drive shaft120. In this manner, partition300operates as a thread follower moving along the threaded portion123as drive shaft120rotates. A drive shaft seal (not shown) may be provided in or on front surface302and/or rear surface304to prevent toner leaking through opening308of partition300. In general, the threaded portion123and threaded hole308have a thread pitch that allows partition300to move along drive shaft120at a speed that does not cause the volume of the second toner compartment129to increase at a rate faster than a rate at which fresh toner is removed from the first toner compartment127. In one example, the thread pitch is selected such that a predetermined number of revolutions of drive shaft120during each toner addition cycle causes partition300to translate a predetermined distance along drive shaft120.

With reference toFIGS. 4A and 4B, when drive shaft120rotates and partition300is positioned on the threaded portion123as shown inFIG. 4A, partition300moves axially along drive shaft120due to the coupling between threaded hole308and threaded portion123. In contrast, when drive shaft120rotates and partition300is positioned on the unthreaded portion124as shown inFIG. 4B, partition300does not move axially along drive shaft120. That is, after partition300moves axially past junction125due to rotation of drive shaft120in its operative rotational direction and partition couples to the unthreaded portion124, partition300stops moving axially toward exit port114even if drive shaft120continues rotating. A stop member131, which may be in the form of a ring, may be positioned along the unthreaded portion124to block partition300from moving further toward exit port114. In another example embodiment, past the location where partition300moves from threaded portion123onto unthreaded portion124, the diameter of unthreaded portion124increases to greater than the diameter of opening308on partition300in order to block partition300from moving further toward exit port114.

The configurations for moving partition300along drive shaft120of toner cartridge35and stopping partition300at a predetermined stop position are not limited to the example embodiments illustrated and other configurations may be implemented. For example, in one alternative embodiment, partition300may move along the threaded portion123of drive shaft120until partition300hits a stop and the threaded central portion of partition300is mechanically disconnected from the partition300, such as by breaking the area surrounding the threaded hole308from partition300. In another alternative embodiment, a coupling member, such as a threaded nut, may be mounted in or on partition300about opening308to movably couple partition300to drive shaft120and allow partition300to move axially when drive shaft120rotates. In another alternative embodiment, a spring loaded nut may be used that is mounted on partition300and held onto the threaded portion123by a spring, and when partition300moves to the end of the threaded portion123of drive shaft120, the nut is pushed toward the center of the drive shaft120onto the unthreaded portion124of the drive shaft120. Other examples are disclosed in U.S. Pat. No. 9,063,460 entitled “Volumetric Toner Cartridge Having Driven Toner Platform” filed on Sep. 14, 2012 and assigned to the assignee of the present application, the content of which is incorporated herein by reference in its entirety. In still other alternative example embodiments, partition300may move within toner cartridge35along drive shaft120of toner cartridge35using other techniques in lieu of or in addition to using a threaded configuration between drive shaft120and partition300.

In one example embodiment, partition300is sealed to prevent toner leakage between the first toner compartment127and second toner compartment129. In one example, a passive bag or bellows (not shown) may be provided within the second toner compartment129, with one end of the bag attached to partition300and the other end of the bag attached to second end106such that the bag expands as partition300moves toward junction125and/or as waste toner enters the second toner compartment129. In another example, a fur seal, woven seal, foam seal, or microfiber fabric may be provided on the edge surface306of partition300adjacent to the inner surface of body102to provide sealing between the first and second toner compartments127,129.

With reference toFIG. 5, a sensing arrangement150is provided for monitoring an axial position of partition300along drive shaft120. Sensing arrangement150includes a plurality of sensors153(shown as sensors153A,153B and153C inFIG. 5) arranged at predetermined axial locations relative to drive shaft120and at least one sensed member156connected to partition300. The plurality of sensors153are communicatively coupled to controller28and are positioned to detect an axial position of the sensed member156relative to the drive shaft120when the toner cartridge35is installed in the imaging apparatus22. In turn, controller28determines an axial position of the partition300along the drive shaft120based on signals received from at least one of the plurality of sensors153.

In one example embodiment, the plurality of sensors153include magnetic sensors and the sensed member156may be or include a permanent magnet detectable by the magnetic sensors153. Magnetic sensors153may be Hall Effect sensors for detecting magnetic field strength(s) from magnetic field lines extending between toner cartridge35and magnetic sensors153, but it is understood that the sensors153may be other types of sensors that are capable of sensing the presence or absence of a magnetic field. Using sensors153, controller28samples or otherwise collects measurements of the magnetic field generated by magnet156on partition300and processes the collected measurements, which includes determining an axial position of partition300along the drive shaft120.

Partition300is movable between an initial position and a final position along drive shaft120. As used herein, the initial position of partition300corresponds to a position of partition300prior to the first use of toner cartridge35and the final position corresponds to a position at which partition300stops and no longer moves along drive shaft120when drive shaft120rotates after toner cartridge35has been used. In the example embodiment illustrated inFIG. 5, the initial position P1of partition300is past the location of waste toner inlet port116, relative to a direction of travel by partition300towards junction125, such that waste toner inlet port116is initially in fluid communication with the second toner compartment129. The first toner compartment127is initially filled with fresh toner (not shown) and the second toner compartment129is initially empty and reserved for storing waste toner. In this example configuration, waste toner delivered by the waste toner transport mechanism95is deposited within the second toner compartment129at the outset of toner cartridge use.

In one example embodiment, magnetic sensors153are positioned within imaging apparatus22proximate an exterior of housing100of toner cartridge35at predetermined axial locations to monitor the axial movement and/or axial position of partition300when toner cartridge35is installed in imaging apparatus22. Magnet156may be positioned in any one of a plurality of positions on the front surface302, rear surface304or edge surface306of partition300, and each magnetic sensor153is positioned so that magnet156passes proximally and/or adjacent thereto when partition300travels axially along drive shaft120. In other example embodiments, each magnetic sensor153is positioned within or as part of toner cartridge35. In this example, each sensor153may communicate measurement readings to controller28via a communication interface between imaging apparatus22and toner cartridge35, such as processing circuitry45associated with toner cartridge35.

Moving partition300along the drive shaft120results in the magnet156being located closer or farther away from a corresponding sensor(s)153, thereby varying the magnetic field strength detected by each sensor153and allowing controller28to determine the location of partition300along drive shaft120. In the example shown, sensor153A is positioned to detect partition300when partition300is at the initial position P1, sensor153B is positioned to detect when partition300is at an intermediate position P2between the initial position P1and final position P3and sensor153C is positioned to detect when partition300reaches the final position P3. Each sensor153may be monitored for the presence or absence of a magnetic field to determine the axial location of partition300. For example, when the movable partition300is at the initial position P1, sensor153A may detect the presence of a magnetic field and the remaining sensors153B,153C may indicate the absence of a magnetic field, indicating the partition300is at the initial position P1. Likewise, sensor153B may detect the presence of a magnetic field and the remaining sensors153A,153C may indicate the absence of a magnetic field when partition300is at the intermediate position P2and sensor153C may detect the presence of a magnetic field and the remaining sensors153A,153B may indicate the absence of a magnetic field when partition is at the final position P3.

In another embodiment, detection by sensors153of the presence of the magnetic field generated by magnet156may overlap. For example, when partition300is at the initial position P1, sensor153A may detect the presence of a magnetic field and the remaining sensors153B,153C may indicate the absence of a magnetic field, indicating the partition300is at the initial position P1. When partition300moves to a position between positions P1and P2, sensors153A and153B may detect the presence of the magnetic field and sensor153C may indicate the absence of a magnetic field, indicating that partition300is located between positions P1and P2. When partition300is at the position P2, sensor153B may detect the presence of a magnetic field and the remaining sensors153A,153C may indicate the absence of a magnetic field, indicating the partition300is at the position P2. When partition300moves to a position between positions P2and P3, sensors153B and153C may detect the presence of the magnetic field and sensor153A may indicate the absence of a magnetic field, indicating that partition300is located between positions P2and P3. Finally, when partition300is at the final position P3, sensor153C may detect the presence of a magnetic field and the remaining sensors153A,153B may indicate the absence of a magnetic field, indicating the partition300is at the final position P3. In other alternative embodiments, controller28may interpolate and/or extrapolate measured data received from sensor(s)153to determine the axial position of partition300on drive shaft120. Although not shown, it is understood that any suitable number of sensors153may be positioned between sensors153A and153C for sensing intermediate positions of partition300between the initial and final positions P1, P3.

In one example embodiment, imaging apparatus22uses information relating to the axial movement and/or position of partition300along drive shaft120to determine a state or condition relating to toner cartridge35. For example, controller28may determine whether toner cartridge35is operating normally, such as whether drive shaft120and paddle assembly200are functioning properly, based on the movement and/or axial position of partition300. During magnetic field measurement, sensor(s)153detect the magnetic field from magnet156and the amount of rotation of drive shaft120is monitored using the encoder of the drive mechanism driving drive shaft120. Since the thread pitch of threaded portion123is known, an expected amount of axial displacement by partition300along drive shaft120may be calculated based on the number of rotations of drive shaft120. Controller28may compare the sensed axial position of partition300, which is based on readings from sensor(s)153, with the expected axial position of partition300as determined based on the number of rotations of drive shaft120. If the sensed axial position corresponds to the expected axial position, an indication may be made that toner cartridge35is operating normally, as expected. A mismatch between the sensed axial position and the expected axial position, however, may indicate that toner cartridge35is not operating normally. For example, if a sensor(s)153is not triggered at an appropriate time at which magnet156is expected to trigger a corresponding sensor153, an indication may be determined that a faulty toner cartridge35has been installed or that toner replenishment is not functioning properly. If it is detected that toner cartridge35is not operating normally, controller28may control imaging apparatus22to respond in a number of ways. In one example, controller28may control imaging apparatus22to provide an error feedback via user interface37. In another example embodiment, the presence of movable partition300and/or axial movement thereof may be used to determine whether toner cartridge35is compatible with imaging apparatus22. Controller28may determine that toner cartridge35is compatible for use with imaging apparatus22upon detection by one or more of sensors153, such as at one or more predetermined axial locations relative to drive shaft120.

In an alternative example embodiment, sensing arrangement150may utilize optical components to monitor the axial movement of partition300along drive shaft120. For example, with reference toFIG. 6, sensing arrangement150includes optical sensors163(shown as optical sensors163A,163B and163C inFIG. 6) positioned on an exterior of housing100and arranged at predetermined axial locations relative to drive shaft120, and a reflective member166disposed on partition300. Reflective member166can be constructed using different combinations of materials to exhibit substantial reflectivity to light in the ultraviolet, visible, or infrared regions of the electromagnetic spectrum, and is readable by each optical sensor163. Each optical sensor163may include an emitter which emits optical energy to reflective member166and a corresponding detector that receives an amount of optical energy reflected by the reflective member166. In this example embodiment, toner cartridge35includes a substantially transparent or transmissive window168to allow optical energy to travel between optical sensor163and reflective member166. The window168may span at least a length corresponding to the range of travel of partition300between its initial position P1and final position P3. In operation, each optical sensor163detects partition300if it is positioned such that reflective member166is located along the optical path of a corresponding optical sensor163to receive and reflect optical energy thereto. Optical sensor163A is positioned to detect partition300when it is at the initial position P1, optical sensor163B is positioned to detect when partition300is at intermediate position P2and optical sensor163C is positioned to detect when partition300reaches its final position P3. Controller28determines an axial position of the partition300along the drive shaft120based on signals received from at least one of the plurality of optical sensors163.

In other alternative example embodiments, sensing arrangement150may utilize other sensing mechanisms to monitor the axial movement of partition300along drive shaft120. In one example, the inner surface of body102of toner cartridge35may include electrical contacts or switches (not shown) arranged at predetermined axial locations relative to drive shaft120that are engaged and triggered by partition300as partition300travels along drive shaft120. In this example, each electrical contact or switch may be communicatively coupled to the processing circuitry45associated with toner cartridge35and processing circuitry45may communicate output signals of each switch to controller28of imaging apparatus22to indicate that partition300is at an axial position corresponding to an axial location of the switch that was triggered. In another example, toner cartridge35may include tab sensors (not shown) that are broken off or pushed out of the side of toner cartridge35when engaged by partition300as partition300travels along drive shaft120. Further, in other embodiments, sensing arrangement150may be used to monitor the position of a passive partition, such as, for example, a bag positioned in reservoir112that receives waste toner entering waste toner inlet port116and expands within reservoir112as the bag fills with toner. For example, the bag may include at least one permanent magnet and magnetic sensors may be positioned to detect whether the bag is in an initial contracted or folded state, one or more partially expanded states or a fully expanded state.

The concept of determining a state or condition of toner cartridge35based on axial movement of a member mounted on drive shaft120may be applied to other toner cartridges with or without a partition therein. For example,FIG. 7illustrates an embodiment of toner cartridge35having a thread follower350, illustrated as an arm350(instead of partition300), mounted on the threaded portion123of drive shaft120that travels along the threaded portion123when drive shaft120rotates. Sensors153are positioned at predetermined axial positions relative to drive shaft120and sensed member156(such as magnet156) is connected to arm350and detectable by the plurality of sensors153. In general, magnet156triggers sensor(s)153when arm350is positioned proximate a corresponding sensor153as arm350travels axially along the drive shaft120when drive shaft120rotates. In one example embodiment, movement of arm350and triggering of sensor(s)153at appropriate locations may be used to indicate that the paddle assembly is operating normally, in the same manner as discussed above with respect toFIG. 5. In this way, other toner cartridges compatible with imaging apparatus22may be used, such as a toner cartridge that includes a waste toner container with fixed volume, a toner cartridge including a bag that provides an expanding waste storage volume, or a toner cartridge that does not include a separate waste toner volume, among many others, by incorporating a thread follower whose axial movement and/or position can be detected by imaging apparatus22.

Referring now toFIGS. 8A-9B, second toner compartment129may include an expandable agitator400that is used to agitate and/or redistribute waste toner therein to prevent waste toner particles from bridging or clumping within second toner compartment129, which could block the deposition of additional waste toner in second toner compartment129. As shown, agitator400is movable between a collapsed state (FIGS. 8A and 9A) and an expanded state (FIGS. 8B and 9B). In general, agitator400is rotatable with drive shaft120and expands as the volume of second toner compartment129expands due to movement of partition300along drive shaft120toward junction125.

FIGS. 8A and 8Bshow agitator400formed in a generally conical or spiral shape and having a first end403and a second end405. In one example embodiment, the first end403of agitator400is fastened to drive shaft120while second end405is rotatably coupled to partition300via a rotary connection407. Fastening or fixedly coupling the first end403allows agitator400to rotate with drive shaft120and coupling the second end405to partition300allows the second end405to move axially with partition300and expand agitator400as partition300moves axially to expand the second toner compartment129. In one example, rotary connection407may include a ball bearing in the shape of a ring having an inner race fixedly attached to partition300and an outer race attached to the second end405of agitator400, or vice versa. Alternatively, the second end405of agitator400may be coupled to drive shaft120so that agitator400is rotated and second end405is driven axially by the rotation of drive shaft120. For example, the second end405may be captured in a keyway cut along drive shaft120or the second end405may have a D-shaped keyway that is received by a flat cut along a length of drive shaft120. In this manner, agitator400is rotated by driving both its first and second ends403,405to rotate with drive shaft120. Alternatively, agitator400may be rotated by driving only the second end405to rotate with drive shaft120, such as by coupling second end405to drive shaft120in a manner previously described. In this example, first end403may be rotatably coupled to end wall110via a rotary connection and rotatable about drive shaft120.

The example embodiment shows spiral agitator400having a diameter that tapers inwardly from end wall110of body102to partition300. It will also be appreciated that a reverse arrangement of spiral agitator400may be implemented wherein its diameter tapers outwardly from end wall110of body102to partition300. In one embodiment, agitator400is made of wire. In another embodiment, agitator400is formed by cutting a spiral from a flat sheet of material. The spiral shape of agitator400allows it to be compressed to a substantially flat sheet when partition300is at an axial position shown inFIG. 8A. Agitator400is fully expanded when partition300is at its final position P3. In other alternative embodiments, agitator400may have curved and/or notched edges.

FIGS. 9A and 9Bshow toner cartridge35including agitator400′ formed in the shape of a helical spring. First and second ends403′,405′ of helical agitator400′ may be connected to drive shaft120and/or partition300in the same manner described above with respect to first and second ends403,405of spiral agitator400. When partition300is at an axial position shown inFIG. 9A, agitator400′ is in the collapsed or compressed state. When partition300is at its stop position P3shown inFIG. 9B, agitator400′ is fully expanded.

In one embodiment, when drive shaft120rotates to rotate paddle assembly200during toner feeding, agitator400rotates with drive shaft120, expanding as its second end405moves together with partition300while agitating and/or moving waste toner within second toner compartment129towards partition300in order to clear the portion of second toner compartment129under waste toner inlet port116to accommodate the receipt of additional waste toner.

In accordance with another example embodiment of the present disclosure, toner cartridge35may be configured such that at least some of the waste toner delivered by the waste toner transfer system36is reincorporated with fresh toner in the first toner compartment127for reuse. Waste toner is produced by incomplete transfer of a toner image from the photoconductive drum80or the intermediate transfer member. Typically, waste toner is contaminated with paper fibers or is of low charge due to extra particulate additives (EPAs) on the toner particle surface. However, shortly after a toner cartridge35is installed, waste toner is almost identical to fresh toner. This type of waste toner comes primarily from the photoconductive drum80and is produced during cycle-up of the imaging apparatus22if the developer bias is temporarily greater in magnitude than the photoconductor bias. Thus, an initial amount of waste toner may be suitable for recycling back into the first toner compartment127and then, after a certain time period, such as after a predetermined number of rotations of drive shaft120or after a predetermined amount of fresh toner has exited the first toner compartment127, waste toner may be deposited into the second toner compartment129.

In the example embodiment shown inFIG. 10A, partition300is initially positioned at an axial position between waste toner inlet port116and end wall110of body102such that waste toner inlet port116is initially in fluid communication with first toner compartment127. Accordingly, an initial amount of waste toner delivered by the waste transport mechanism95is reincorporated with fresh toner (not shown) in the first toner compartment127at the outset of toner cartridge use. As drive shaft120rotates in its operative rotational direction, partition300moves from its initial position P1′ to an intermediate position P2′ past waste toner inlet port116, relative to the direction of travel of partition300toward junction125, as shown inFIG. 10B. In the intermediate position P2′, waste toner inlet port116is in fluid communication with the second toner compartment129such that remaining waste toner is deposited within the second toner compartment129. As with above example embodiments, sensors may be employed within imaging apparatus22at predetermined axial locations relative to drive shaft120to monitor the location of partition300as it moves along drive shaft120until partition300reaches its final position P3′.

In another example embodiment illustrated inFIGS. 11A and 11B, a waste tube197passes through an opening180provided in end wall110of toner cartridge35. Partition300is also provided with an opening320that is aligned with the opening180in end wall110and sized to receive waste tube197. In order to reincorporate an initial amount of waste toner into the first toner compartment127, partition300is initially positioned such that waste tube197passes through opening320and a waste toner exit end198of waste tube197extends into the first toner compartment127as shown inFIG. 11A. Partition300may include a shutter325that is movable with respect to waste tube197between an open position and a closed position. When waste tube197passes through opening320of partition300and waste toner exit end198extends into the first toner compartment127, shutter325is in the open position and waste toner is deposited into the first toner compartment127. During toner feeding, drive shaft120rotates in its operative rotational direction causing partition300to travel axially away from the end wall110. When partition300moves past the waste tube exit end198, shutter325moves to the closed position to cover opening320and prevent fresh toner in the first toner compartment127from entering the second toner compartment129and waste toner is deposited into the second toner compartment129. In one example, shutter325is spring loaded closed and pushed open by waste tube197.

The configurations for reincorporating waste toner with fresh toner are not limited to the example embodiments shown inFIGS. 10A-11B. Other configurations are possible. For example, partition300may include a valve (not shown) that, when open, allows waste toner in the second toner compartment129to flow through an open section at a bottom portion of partition300into the first toner compartment127. Moving waste toner in the second toner compartment129towards partition300, through the open section, and into the first toner compartment127to reincorporate waste toner with fresh toner in the first toner compartment127may be accomplished by providing an agitator, such as agitator400′, in the second toner compartment129. After partition300moves to a predetermined axial position, the valve may be triggered, such as by a projection within toner cartridge35or by a magnet adjacent toner cartridge35, to close off the open section and prevent waste toner in the second toner compartment129from entering the first toner compartment127.

In another example, waste toner transfer system36may include a first waste tube (not shown) for transporting waste toner into the first toner compartment127and a second waste tube (not shown) for transporting waste toner into the second toner compartment129. In this example, two separate waste toner entry points may be provided which are in fluid communication with the first toner compartment127and second toner compartment129and receive waste toner from the first and second waste tubes, respectively. The partition dividing the toner reservoir may be movable as described in the above example embodiments or fixed such that the first and second toner compartment volumes are fixed. A valve (not shown) may be provided to control the flow of waste toner to either the first toner compartment127or the second toner compartment129. For example, the valve may be controllable to selectively switch the flow of waste toner between the first waste tube and second waste tube to deposit waste toner within the first toner compartment127or second toner compartment129, respectively. In one example, the valve switches from the first waste tube to the second waste tube when partition300passes a predetermined axial position along drive shaft120. In another example, the switch is triggered when the print count from toner cartridge35reaches a preset value.

The foregoing description illustrates various aspects and examples of the present disclosure. It is not intended to be exhaustive. Rather, it is chosen to illustrate the principles of the present disclosure and its practical application to enable one of ordinary skill in the art to utilize the present disclosure, including its various modifications that naturally follow. All modifications and variations are contemplated within the scope of the present disclosure as determined by the appended claims. Relatively apparent modifications include combining one or more features of various embodiments with features of other embodiments.