Collapsible packaging system

A printing machine including a material supply module adapted to expel a marking material contained in a collapsible package having an information-bearing tag. The material supply module includes a reader for obtaining information from the information-bearing tag, a package opening actuator configured to cause the collapsible package to open, and at least one hopper for receiving the marking material. The printing machine also includes a marking device module configured to receive the marking material from the at least one hopper. Other aspects are a method of supplying marking material and a method of verifying the contents of a marking material package.

BACKGROUND

A common trend in machine design is to organize a machine on a modular basis, wherein certain distinct subsystems of the machine are bundled together into modules, which can be readily removed from the machine and replaced with new modules of the same or similar type. A modular design facilitates great flexibility in the business relationship with the customer. By providing subsystems in discrete modules, visits from a service representative can be made very short, since all the representative has to do is remove and replace a defective module. Actual repair of the module may take place remotely at the service provider's premises. As another alternative, some modules lend themselves to replacement by the customers themselves, and these are often referred to as “customer replaceable unit monitors” or “CRUMS.” Further, some customers may wish to have the ability to buy modules “off the shelf,” such as from an equipment supply store. Indeed, it is possible that a customer may lease the machine and wish to buy a supply of modules as needed. Further, the use of modules, particularly for expendable supply units (e.g., copier and printer toner bottles) are conducive to recycling activities. In addition, modules may be used for anti-theft or security purposes, for example, where the module may be removed by the user to disable the machine (e.g., face plates on automobile radios and wireless network cards installed in laptop computers).

For machines that require replenishment of materials on a regular basis, a modular design may be particularly useful. Materials may be pre-packaged in a manner that makes them easily introduced to a relevant module. Unfortunately, for some types of materials, e.g., toner, ink, and other printing materials, oftentimes current modular designs fail to solve the unwanted problems of material spills and difficult to dispose of expended material packaging.

BRIEF SUMMARY

According to one aspect, there is provided a printing machine including a material supply module adapted to expel a marking material contained in a collapsible package having an information-bearing tag. The material supply module includes a reader for obtaining information from the information-bearing tag, a package opening actuator configured to cause the collapsible package to open, and at least one hopper for receiving the marking material. The printing machine also includes a marking device module configured to receive the marking material from the at least one hopper.

According to another aspect, there is provided a method of supplying marking material including the following steps: feeding a package having an information-bearing tag into a housing of a printing machine; reading the information-bearing tag to verify the marking material contained in the package; and opening the package at least partially within the housing to expel the marking material from the package.

According to yet another aspect, there is provided a method of verifying the contents of a marking material package, which includes the following steps: feeding a package having an information-bearing tag into a housing of a printing machine; reading the information-bearing tag to verify the marking material contained in the package; rejecting the package according the marking material contained in the package; and ejecting the package from the housing before it has been collapsed.

DETAILED DESCRIPTION

FIG. 1is a schematic depiction of a machine10including replaceable modules12and14, also known as “customer replaceable units” or CRUs. For purposes of discussion herein, machine10is depicted as a printing apparatus, such as a digital printer of the ink jet or “laser” (electrophotographic or xerographic) variety, or a digital or analog copier. Modules12and14are depicted as hardware devices related to printing, such as a marking material supply module and a marking device module, respectively. In the embodiment ofFIG. 1, marking material supply module12is adapted to receive and collapse a package16, which contains a predetermined amount of a material18, e.g., a marking material such as a toner, ink, or similar. Package16, which is generally collapsible, typically includes an information-bearing tag17, which may identify material18, the amount of material remaining in the package, or other information. Material18is supplied to marking device module14. It is contemplated, however, that machine10may be any electrical, electronic, mechanical, electromechanical device configured to perform one or more functions, and that marking material supply module12may be any component, group of components, system, or subsystem of the machine and material18may include any material, e.g., marking materials such as solid and liquid toners and inks, non-marking materials, chemical pellets, etc. It is also contemplated that marking material supply module12may or may not be removable from machine10.

Referring now toFIG. 2, in one embodiment, marking material supply module12is generally self-contained and includes a hopper20and a package opening actuator22, which is positioned within the hopper and configured to cause package16to open.

Hopper20includes an at least partially enclosed chamber24having a plurality of walls26and an opening28. At least one of walls26is configured to facilitate movement of material18toward opening28when package16is situated in hopper20. In one embodiment, one or more of walls26are angled so that material18gravity feeds toward opening28. In other embodiments, walls26may include paddles, grooves, or other mechanical mechanisms to facilitate movement of material18toward opening28. One or more of walls26may include a mechanism for guiding package16within hopper20. In one embodiment, the mechanism includes one or more material package guide tracks30, which are operatively connected with at least one of walls26. In another embodiment, more than one mechanism may be included and more than one hopper20may be included. For example, a first mechanism may be used to direct black marking material to a first hopper and a second mechanism may be used to direct color marking material to a second hopper.

Opening28is typically a material outlet, which is defined in or adjacent to one or more of walls26. InFIG. 2, opening28is defined in between four slanted or angled walls26. In other embodiments, opening28may be an aperture defined within a single wall or an opening defined between any number of walls. For example, in an embodiment having a single wall (not shown), the single wall may be frusto-conically shaped to define a funnel with an opening. In addition to opening28, a package inlet32may be defined in or adjacent to one or more of walls26. Package inlet32may include a door/slot combination or any other configuration through which package16may be inserted into hopper20. Although not included inFIG. 2, it is contemplated that more than one package inlet32may be included. For example, a first package inlet may be used to insert black marking material and a second package inlet may be used to insert color marking material. In one embodiment, a reader33may be positioned within marking material supply module12to read information-bearing tag17. Typically, reader33is positioned in hopper20adjacent package inlet32. Reader33is generally capable of reading tags using radio frequency identification (RFID) technology, bar coding, or any machine-readable coding. In some embodiments, reader33may also be capable of transmitting data to information-bearing tag17.

In one embodiment, package opening actuator22may include two or more pressure rollers34configured to introduce pressure to package16. Typically, a pressure roller drive motor36is included to drive pressure rollers34. Typically, motor gears38, which are joined with and driven by pressure roller drive motor36, mesh with at least one of roller gears40, which are joined with each of rollers34and engaged with one another, thereby driving pressure rollers34. Pressure rollers34are typically configured to develop a pressure within package16sufficient to cause the package to collapse thereby causing material18contained with the package to deposit into hopper20or directly into opening28. Package opening actuator22is not limited to pressure rollers34but may include any mechanical or thermal mechanisms, which successfully cause package16to open or collapse. In one embodiment, pressure rollers34may rotate in a direction sufficient to cause package16to be ejected from machine10. For example, based on the information obtained by reader33, it may be determined that the wrong marking material has been inserted and therefore package16should be rejected and ejected from machine10before it is collapsed or opened. Accordingly, pressure rollers34may be directed to rotated in a manner to cause package16to be ejected from machine10before it has been opened. In other embodiments not having pressure rollers34, other mechanisms for ejecting package16may be utilized. In still other embodiments, machine10may include mechanisms for ejecting package16after it has been opened. For example, after an opened package16may exit pressure rollers34and be directed out of machine10through an additional opening (not shown) in hopper20.

Marking material supply module12may also include a waste collection area42, which is typically configured to receive and store each package16after material18is expelled. For example, after a period of use, waste collection area42may contain a plurality of opened packages16. In some embodiments, waste collection area42may be accessible to allow for removal of waste packages16. In other embodiments, waste collection area42may be inaccessible to a user of machine10. In such an embodiment, waste packages16may remain in machine10for the life of the machine. In still other embodiments, waste collection area42may include mechanisms for disintegrating any packages contained therein, e.g., chemical, heat, or other systems.

Referring now toFIG. 3, another embodiment includes a method50of supplying material contained in a package. First at step52, package16, which includes information-bearing tag17, is fed into a housing such as hopper20. Next at step54, edges of package16are typically aligned with guide tracks such as material package guide tracks30as package16is fed into hopper20. Then, at step56, the material such as material18is verified in package16without visually inspecting the collapsible package, e.g. reader33reads information-bearing tag17. Next, at step58, package16is collapsed while the collapsible package is at least partially within hopper20to expel material18from the collapsible package. Typically, package opening actuator22is used to open package16. Generally, package inlet32is closed and sealed when package16is opened to prevent material18from exiting hopper20. Finally, method50may include the additional step (not shown inFIG. 3) of storing each of package16after it has been collapsed or opened.

Referring now toFIGS. 4 and 5, package16, which is suitable for use in material supply module12, includes a package surface60, which is adapted to engage one or more surfaces (not shown) of material supply module12. Package surface60includes side edges62, which may be adapted to engage material package guide tracks30of hopper20. A material pouch64, which may contain material18, is joined with or formed in package surface60. Material pouch64typically includes a burst line66, which is adapted to burst when placed under a predetermined pressure, heated to a predetermined temperature, or mechanically penetrated. In one embodiment, material pouch64is adapted to be refilled with material, e.g., particulate solid ink, and burst line66is adapted to be resealed after it is burst, e.g., includes a “zip-lock”, re-sealable adhesive portion, or similar enclosure. Typically, burst line66is a portion of material pouch64that has a lower tensile or puncture strength than other portions of the material pouch. Material pouch64is typically flexible and/or collapsible and generally has a substantially flat shape when fully collapsed. In one embodiment, material pouch64is light transmissive so that at least the color of the contents of the pouch may be viewed from the outside. Package16may also include a material identifier mechanism formed on package surface60or material pouch64, e.g., information-bearing tag17, one or more keys70, or similar, for verifying the contents of collapsible material pouch18. Information-bearing tag17may include radio frequency identification technology, a bar code, any machine-readable code, or any technology suitable for such an application. Keys70may be mechanical keys or optical keys. In embodiments including optical keys, reader33may be adapted to interact with the optical keys.

In use, machine10may include a controller80, which generally controls the operation of the machine. When modules12and14are installed in machine10, controller80communicates with the modules via data paths, which are indicated by double-ended arrows inFIG. 1. In addition, data may be communicated between a device82external to machine10and controller80. Controller80may also communicate with users through a user interface84or through a network connection86, such as over phone lines or the Internet.

In operation, sheets on which images are to be printed are drawn from a stack88and move relative to the marking device module14, where the individual sheets are printed upon with desired images. The marking material for placing marks on various sheets by marking device module14is provided by marking material supply module12. If machine10is an electrostatographic printer, marking material supply module12may include a supply of solid or liquid toner, while marking device module14includes any number of hardware items for the electrostatographic process, such as a photoreceptor or fusing device. In the well-known process of electrostatographic printing, the most common type of which is known as “xerography,” a charge retentive surface, typically known as a photoreceptor, is electrostatically charged, and then exposed to a light pattern of an original image to selectively discharge the surface in accordance therewith. The resulting pattern of charged and discharged areas on the photoreceptor form an electrostatic charge pattern, known as a latent image, conforming to the original image. The latent image is developed by contacting it with a finally divided electrostatically attractable powder known as “toner.” Toner is held on the image areas by the electrostatic charge on the photoreceptor surface. Thus, a toner image is produced in conformity with a light image of the original being reproduced. The toner image may then be transferred to a substrate, such as paper from the stack88, and the image affixed thereto to form a permanent record of the image.

In the ink-jet context, the marking material supply module12includes a quantity of liquid ink, and may include separate tanks for different primary-colored inks, while marking device module14includes a printhead. In either the electrostatographic or ink-jet context, “marking material” can include other consumed items used in printing but not precisely used for marking, such as oil or cleaning fluid used in a fusing device. Of course, depending on a particular design of a machine10, the functions of modules12and14may be combined in a single module, or alternatively, the marking device may not be provided in an easily replaceable module such as14. Further, there may be provided several different marking material supply modules12, such as in a full color printer. In general, for purposes of the present embodiment, there may simply be provided one or more replaceable modules associated with machine10, and it is expected that, at times within the life of machine10, one or more of these modules need to be removed or replaced. In the current market for office equipment, for example, it is typically desirable that modules such as12and14be readily replaceable by the end user, thus saving the expense of having a representative of the vendor visit the user.

Referring now toFIGS. 6 and 7, in an alternative embodiment, a collapsible package90, which is suitable for use in material supply module12, includes a package surface60. Collapsible package90includes a collapsible material pouch92and a material identifier mechanism such as a radio frequency identification tag94, one or more keys96, or similar, for verifying the contents of the collapsible material pouch while the pouch is at least partially inserted in the material supply module. Collapsible material pouch92includes side edges98and a top edge100, which may be adapted to engage material package guide tracks30of hopper20. Collapsible material pouch92typically includes a burst line102, which is adapted to burst when placed under a predetermined pressure, heated to a predetermined temperature, or mechanically penetrated.

Referring now toFIGS. 8 and 9, in another alternative embodiment, a collapsible package110, which is suitable for use in material supply module12, includes a reusable carrier112and a collapsible material pouch114joined with the carrier. Reusable carrier112and collapsible material pouch114may be joined using a snap-fit connection116, which includes indents118formed in the reusable carrier that releasably connect with detents120formed in the collapsible material pouch. Of course, any other types of connections known in the art or otherwise, which permit collapsible material pouch114to be releasably connected with reusable carrier112, may be used. Reusable carrier112is typically adapted to engage one or more surfaces of material supply module12to facilitate loading of collapsible package110into the module. Reusable carrier112is typically fabricated from plastic but may also be fabricated from paper, cardboard, or any other reusable durable material. Collapsible material pouch114is typically fabricated from plastic or foil, but may be fabricated from any lightweight collapsible material. Collapsible material pouch includes a burst line119. Collapsible material pouch114is typically discarded after burst line119is broken and the pouch is collapsed. However, in at least one embodiment, burst line119may be resealed and collapsible material pouch114may be refilled and reused. Collapsible reusable carrier112and collapsible material pouch114may include a material identifier mechanism such as a radio frequency identification tag122, one or more keys124, or similar, for verifying the contents of the collapsible material pouch. In one embodiment, radio frequency identification tag122on reusable carrier112may be joined with the radio frequency identification tag or other data source on collapsible material pouch114via a wire126or similar electrical connection for communicating data. In such an embodiment, for each different type of material, collapsible material pouch114may include a different identifying code, which is transmitted to radio frequency identification tag122on reusable carrier112via wire126. In use, collapsible package110may be refilled by first providing reusable carrier112and then joining an un-collapsed collapsible material pouch114with the carrier.

Referring again toFIGS. 6 and 7, another embodiment includes a method of remanufacturing a package90suitable for containing marking material used in a printing machine10. First, an at least partially empty material pouch92is provided. Material pouch92is adapted to engage one or more surfaces of printing machine10and includes both an unsealed burst line102and an information-bearing tag94for verifying its contents. Next, material pouch92is at least partially filled with marking material. Then, burst line102is sealed. An additional step may include altering data associated with information-bearing tag94.

Still referring toFIGS. 6 and 7, another embodiment includes a method of remanufacturing a package90suitable for containing marking material used in a printing machine. The method includes the first step of providing an at least partially empty material pouch92, which includes an information-bearing tag94for verifying the contents of the material pouch. Next, information-bearing tag94is removed. Then, a replacement material pouch (not shown) that is substantially full of marking material is provided. Finally, information-bearing tag94is attached to the replacement material pouch. An additional step may include altering data associated with information-bearing tag94.

Now again referring toFIGS. 8 and 9, another embodiment includes a method of remanufacturing a package110suitable for containing marking material used in a printing machine. The method includes the first step of providing a carrier112, which is adapted to engage one or more surfaces of printing machine10. Next, a material pouch114containing marking material is joined with carrier112.

Still referring toFIGS. 8 and 9, another embodiment includes a method of remanufacturing a package110suitable for containing particulate solid ink used in a printing machine10. The method includes the first step of providing a material pouch114that is at least partially empty of particulate solid ink. Material pouch114includes an unsealed burst line119and an information-bearing tag122for verifying the contents of the material pouch. Next, material pouch114is at least partially filled with particulate solid ink. Then, burst line119is sealed. Next, a carrier112, which is adapted to engage one or more surfaces of printing machine10, is provided. Finally, material pouch114is joined with carrier112.

It should be understood that any of the features, characteristics, alternatives, or modifications described regarding a particular embodiment herein may also be applied, used, or incorporated with any other embodiment described herein.