High speed nozzle for toner filling systems

Abstract: An apparatus for assisting in filling a container from a hopper containing a supply of powder is provided. The apparatus includes a conduit (36) operably connected to the hopper and extending downwardly therefrom. The conduit is adapted to permit a flow of powder therewithin. The apparatus also includes a nozzle (34) operably connected to the conduit and extending downwardly therefrom. The nozzle defines an inlet thereof for receiving powder from the conduit and defines an outlet thereof for dispensing powder from the nozzle to the container. The inlet defines an inlet cross sectional area perpendicular to the flow the powder and an outlet defining an outlet cross sectional area perpendicular to the flow the powder. The inlet cross sectional area is larger than the outlet cross sectional area. The apparatus further includes an conveyor located at least partially within the conduit. The conveyor assists in providing the flow of powder from the container. The dimensions of the nozzle are selected so as to provide a ratio of the inlet cross sectional area to the outlet cross sectional area such that the flow of powder does not seize as it progresses through the nozzle.

Description: The invention relates to an apparatus for assisting in filling a container from a hopper containing a supply of powder according to the preamble of claim 1. Such an apparatus is known from US-A-5226863. A similar apparatus is known from US-A-1452585. Currently when filling powders, for example toners into toner containers, toner is transported from the toner supply hopper into the container by a rotating auger. The auger is a spiral shaped mechanical part which pushes particles of toner inside a fill tube by direct mechanical contact. The nature of this mechanical contact process creates substantial limitations on accuracy and productivity of the toner filling operation. The speed of the toner movement in the fill tube is proportional to the speed of rotation of the auger and is limited by heat release due to auger/toner friction. High auger speed will cause the toner to melt, particularly for low melt toner such as disclosed in US-A 5,227,460 to Mahabadi et al. the relevant portions thereof incorporated herein by reference. To provide for productive efficient toner containers, typically, the rotating augers used to transport the toner from hoppers are relatively large. The large augers provide for high volume toner flow and thus improve productivity in a fill line. When utilizing such fill lines for small, low cost copiers and printers, difficulties occur in that the openings in the toner containers utilizing such small copiers and printers include a small toner fill opening that may have an irregular shape and have a fill opening that is not centrally located in the container. Problems are thus associated with fitting the large filling tubes and augers with the small toner fill openings. Problems with filling containers with toner are exacerbated in that the small low cost copies are produced in higher quantities necessitating very efficient toner filling operations. Problems with efficient toner filling are also apparent in small and medium cost multi-colored highlight or full color printers and copiers. The toner containers for color toner typically are smaller than those for black toner and also more typically have an irregular shape. Further, color toners have been developed with smaller particle size of for example 7 microns or less. These smaller toners are more difficult to flow through toner hoppers and are more difficult to be translated along augers. Toner containers for small low cost printers and copiers typically have a small opening into which the toner is to be added. Furthermore, the toner containers often have irregular shapes to conform to the allotted space within the copying machine. Therefore it becomes difficult to fill the toner container because of the small tube required to fit into the small toner container opening and secondly for all the toner within the container to completely fill the remote portions of the container before the container overflows. The problems associated with controlling the filling of toner containers are due primarily to the properties of the toner. Toner is the image-forming material in a developer which when deposited by the field of an electrostatic charge becomes the visible record. There are two different types of developing systems known as one-component and two-component systems. In one-component developing systems, the developer material is toner made of particles of magnetic material, usually iron, embedded in a black plastic resin. The iron enables the toner to be magnetically charged. In two-component systems, the developer material is comprised of toner which consists of small polymer or resin particles and a color agent, and carrier which consists of roughly spherical particles or beads usually made of steel. An electrostatic charge between the toner and the carrier bead causes the toner to cling to the carrier in the development process. Control of the flow of these small, abrasive and easily charged particles is very difficult. The one-component and two-component systems utilize toner that is very difficult to flow. This is particularly true of the toner used in two component systems, but also for toner for single component systems. The toner tends to cake and bridge within the hopper. This limits the flow of toner through the small tubes which are required for addition of the toner through the opening of the toner container. Also, this tendency to cake and bridge may cause air gaps to form in the container resulting in partial filling of the container. Attempts to improve the flow of toner have also included the use of an external vibrating device to loosen the toner within the hopper. These vibrators are energy intensive, costly and not entirely effective and consistent. Furthermore, they tend to cause the toner to cloud causing dirt to accumulate around the filling operation. Also, difficulties have occurred in quickly starting and stopping the flow of toner from the hopper when filling the container with toner in a high speed production filling operation. An electromagnetic toner valve has been developed as described in U.S. Patent Applications, Serial Numbers 08/540,993 and 08/690,412, assigned to the same assignee as this application, the relevant portions incorporated herein by reference. The electromagnetic valve is limited for use with magnetizable toner such as that described for use with one component development systems. Attempts have been made to fill toner containers having small toner fill openings by utilizing adapters positioned on the end of the toner filling auger which has an inlet corresponding to the size of the auger and an outlet corresponding to the opening in the toner container. Clogging of the toner, particularly when attempting to increase toner flow rates and when utilizing toners with smaller particle size, for example, color toners having a particle size of 7 microns or less, has been found to be a perplexing problem. The adapters that are fitted to the augers, thus, tend to clog with toner. The flow rates through such adapters is unacceptably low. Further, the use of these adapters may create problems with maintaining a clean atmosphere free of toner dust at the filling operation. The object of the invention is to improve an apparatus for assisting in filling a container from a hopper containing a supply of powder such that it will be possible to fill reliably even remote portions of a container before the container may overflow. This object is achieved by an apparatus comprising the features of claim 1. Advantageous developments are set forth in the dependent claims. In accordance with the present invention, there is provided an apparatus for assisting in filling a container from a hopper containing a supply of powder, particularly a supply of toner. The apparatus includes a conduit operably connected to the hopper and extending downwardly therefrom. The conduit is adapted to permit a flow of powder therewithin. The apparatus also includes a nozzle operably connected to the conduit and extending downwardly therefrom. The nozzle defines an inlet thereof for receiving powder from the conduit and defines an outlet thereof for dispensing powder from the nozzle to the container. The inlet defines an inlet cross sectional area perpendicular to the flow the powder and the outlet defines an outlet cross sectional area perpendicular to the flow the powder. The inlet cross sectional area is larger than the outlet cross sectional area. The apparatus further includes a conveyor located at least partially within the conduit. The conveyor assists in providing the flow of powder from the container. The dimensions of the nozzle are selected so as to provide a ratio of the inlet cross sectional area to the outlet cross sectional area such that the flow of powder does not seize as it progresses through the nozzle. Figure 1 is a cross-sectional schematic view of a high speed nozzle for developer material; Figure 2 is an elevational view of a container filling system partially in section utilizing the nozzle of Figure 1 showing the deflector in use to disperse the developer material with the filling system in the filling position; Figure 3 is a elevational view of a container filling system partially in section utilizing the nozzle of Figure 1 showing the deflector in use to disperse the developer material with the filling system in the indexing position; Figure 4 is a side view of the container filling system of Figure 2; Figure 5 is an elevational view of a container for use with the high speed nozzle of Figure 1 without the deflector showing the filling of the container; Figure 6 is an elevational view of a container for use with the high speed nozzle of Figure 1 showing the deflector in use to disperse the developer material; Figure 7 is a cross-sectional schematic view of a second alternate embodiment of the high speed nozzle for developer material of the present invention utilizing a nozzle with an air boundary for reduced friction. According to the present invention and referring now to Figure 2, powder filling assisting apparatus 10 is shown. The powder filling assisting apparatus 10 is used to convey powder 12 in the form of toner for use in a copier or printer from a hopper 14 to a container 16. The powder filling apparatus 10 is mounted to filling line 20 preferably to permit for the filling of large production quantities of containers 16, the container 16 is preferably mounted to a carrying device 22. The device 22 is movable in the direction of either arrow 24 or 26. The carrying device 22 serves to position container centerline 30 in alignment with apparatus centerline 32. The powder filling assisting apparatus 10 includes a nozzle 34 which is used to direct the powder 12 into the container 16. The nozzle 34 is connected to the hopper 14 by means of a conduit 36 preferably in the form of a hollow tube or funnel. As shown in Figure 2, the hopper 14 is positioned above the container 16 whereby gravity will assist in the flow of powder 12 toward the container 16. To optimize the flow of powder 12 toward the container 16, the powder filling apparatus 10 further includes a conveyor 40 positioned at least partially within the conduit 36 for assisting in the flow of the powder 12. The conveyor 40 is preferably in the form of a spiral conveyor or auger. For example, the auger 40 may be in the form of a spiral shaped auger. Preferably, the nozzle 34 is insertable into opening 42 of the container 16. The insertion of the nozzle 34 in the opening 42 may be accomplished in any suitable method. For example, the carrying device 22 and, consequently, the container 16 may be movable upward in the direction of arrow 44 for engagement with the nozzle 34 and downward in the direction of arrow 46 for disengagement from the opening 42. The upward and downward motion of the device 22 and the container 16 permits the container 16 to be indexed in the direction of arrows 24 and 26. To permit the filling of a number of containers 16, the flow of powder 12 from the hopper 14 must be halted during the indexing of a filled container 16 from the fill position and during the indexing of the unfilled container 16 toward the filling position. As shown in Figure 2, the flow of powder 12 may be halted by the stopping of auger 40 within the conduit 36. The auger 40 may be rotated by any suitable method, i.e. by motor 50 operably connected to the auger 40. The motor 50 is connected to a controller 52 which sends a signal to the motor 50 to stop the rotation of the auger 40 during indexing of the carrying device 22. It should be appreciated, however, that the flow of powder 12 through the conduit 36 may be further controlled by the use of a valve (not shown). Preferably, provisions are made to assure that the filling line 20 is free from airborne powder 12 which may escape between the nozzle 34 and the opening 42 of the container 16 during the filling operation and in particular during the indexing of the carrying device for presenting an unfilled container 16 to the powder filling apparatus 10. A clean filling system 54 is shown in Figure 2 for use with the apparatus 10. The clean filling system 54 preferably includes housing 56. The housing 56 is secured to filling line 20 as well as to the conduit 36. The housing 56 may serve several purposes. For example, the housing 56 may be used to support slide 60. Slide 60 is connected to a tray 61 which slidably is fitted between the nozzle 34 and the opening 42. The tray 61 may have any suitable form and , as shown in Figure 2 may be in the form of a toner drip plate. The tray 61 has a first position in which the tray 61 prevents the powder 12 from exiting the nozzle 34. In this extended position, the tray 61 prevents the spilling of powder 12 during the indexing of the containers 16. The tray 61 also has a second retracted position for permitting the powder 12 to flow into the container 16 during filling. The housing 56 preferably also provides a second purpose, namely, to support the conduit 36 and the nozzle 34. Also, the housing 56 surrounds the nozzle 34 and provides a cavity or chamber 62 which is sealed when the tray 61 is in its closed position. The chamber 62 preferably is kept at a vacuum. The chamber may be maintained at a vacuum in any suitable fashion, e.g. the chamber 62 may be connected by toner dust vacuum line 64 to vacuum source 66. The vacuum source 66 may be in the form of a toner recovery booth. The housing 56 also may preferably provide an additional function. The housing 56 serves as a registration guide for guiding the nozzle 34 into the opening 42. As shown in Figure 2, the housing 56 includes a chamfered end 70 which as the container 16 moves in the direction of arrow 44, contacts the opening 42 to register and align the powder filling assisting apparatus 10 with the container 16. Preferably, the housing 56 is slidably mounted to the conduit 36 such that the housing 56 may move upwardly in the direction of arrow 72 and downwardly in the direction of arrow 74. It should be appreciated that the sliding motion of the housing 56 may be accomplished by gravity or by springs as well as by a motor or other mechanism. For example, the housing 56 may be moved upwardly in the direction of arrow 72 by the container 16 moving upwardly in the direction of arrow 44. The nozzle 34, thereby, enters into the opening 42 permitting filling. Concurrently with the raising of the container 16 to engage with the nozzle 34, the tray 61 is moved to the left in the direction of arrow 76 to permit the powder 12 to flow through the nozzle 34 and into the container 16. It should be appreciated that the tray 61 may be actuated in any manner, for example, by means of a motor or other mechanism, but, as shown in Figure 2, the tray 61 is preferably operated by a cam mechanism 80 interconnected to the housing 56 such that when the housing 56 moves in the direction of arrow 72, the tray 61 moves in the direction of arrow 76 opening the chamber 62 to communication with the container 16. Figure 2 shows the powder filling assisting apparatus 10 in the container up position to enable filling of the container 16. The nozzle 34 is positioned in the opening 42 of the container and the tray 61 is retracted in the position of arrow 76 to permit the flow of toner 12. Referring now to Figure 3, the powder filling assisting apparatus 10 is shown with in the container down position to enable indexing of the carrying device 22. The carrying device 22 indexes the filled container out of the fill position and indexes the unfilled container into the fill position. The nozzle 34 is removed from the opening 42 of the container 16 in this position. The tray 61 is extended into the chamber 62 to catch any dripping toner residue. Referring now to Figure 1, the nozzle 34 is shown in greater detail. The nozzle 34 may be made of any suitable durable material, e.g. a plastic or a metal that is chemically non-reactive with the powder 12. For example, the nozzle 34 may be made of stainless steel. The nozzle may have any suitable shape but includes an inlet 82 adjacent the conduit 36 as well as an outlet 84 opposed to the inlet 82. The nozzle 34 is secured to the conduit 36 in any suitable fashion. For example, as shown in Figure 1, the nozzle 34 is press fitted over the conduit 36. It should be appreciated that the nozzle may be secured to the conduit by means of fasteners, glue or by welding. Preferably, extending inwardly from the outlet 84 are guide tabs 86 which serve to guide the nozzle 34 into the opening 42 of the container 16. Between the inlet 82 and the outlet 84 of the nozzle 34 is a central portion 90 of the nozzle. The central portion 90 preferably has a hollow substantially conofrustrical shape or funnel like shape. To assist in the flow of powder 12 within the interior of the nozzle 34, the central portion 90 of the nozzle 34 preferably is coated on inner periphery 92 of the nozzle 34 with a coating 94. The coating 94 is preferably made of a material with a low coefficient of friction. A coefficient of friction of less than 0.25 is preferred. Polytetrafluoroethylene is particularly well suited for this application. The auger 40 is rotatably secured within the conduit 36. The auger 40 may float within the conduit 36 or be supported to the conduit 36 at its distal ends. The auger 40 may be of any particular configuration but preferably is a spiral auger. The auger 40 rotates at a suitable speed to optimize the flow of powder 12 through the nozzle 34. For example, for a conduit 36 having a diameter B of 3.175 cm (1.25 inches), the auger 40 preferably has an auger diameter A of approximately 2.54 cm (1.0 inches). For an auger with an auger diameter A of 2.54 cm (1.0 inches), the auger 40 may rotate at a rotational speed of approximately 500 rpm. For the auger with an auger diameter A of 2.54 cm (1.0 inches), the auger 40 may have pitch P or distance between adjacent blades of the auger of approximately 2.54 cm (1.0 inches). It should be appreciated that the optimum rotational speed of the auger 40 is dependent on the value of the pitch P. As shown in Figure 1, the auger 40 may terminate at the inlet portion 82 of the nozzle. The invention may be practiced with the central portion 90 of the nozzle 34 including an empty cavity or chamber 96. The nozzle 34 is designed such that the nozzle has an inlet diameter IND at inlet 82 which is larger than outlet diameter OUD such that the flow of powder for a given auger and rotational speed may be maximized. It should be appreciated that different powders have different densities and thus the dimensions of IND and OUD need to be varied for optimum flow of the powder. For example, as shown in Figure 1, for a toner having a particles size of approximately 7 microns and utilizing an auger 40 with a rotational speed of 500 rpms, the inlet diameter IND is approximately 3.175 cm (1.25 inches) and the outlet diameter OUD is approximately 2.22 cm (.875 inches). For a nozzle with a distance between the inlet and outlet or height H of the central portion of approximately 1.78 cm (0.7 inches), the included angle α of the inner periphery 92 of the nozzle 34 is approximately 20 degrees. When utilizing the nozzle 34 to fill containers having an opening which is not concentric with the container, the use of a deflector 100 is preferred. Preferably, the deflector 100 is mechanically connected to the auger 40 and rotates therewith. As shown in Figure 1, the deflector 100 is connected to holder 102. Holder 102 is secured to auger 40 by any suitable means. For example, the holder 102 is secured to auger 40 by means of threads 104. The deflector 100 may be made of any suitable material. For example, the deflector may be made of plastic or metal. The deflector 100 may be made of stainless steel. As shown in Figure 2, the deflector 100 is in the form of deflector blades. While the deflector 100 may be made from a single blade, preferably the deflector 100 includes a plurality of equally spaced blades around holder 102. As shown in Figure 1, the deflector blade has a width W of approximately 1.52 cm (0.60) inches for use when the nozzle 34 has an OUD of 2.22 cm (.875 inches) Preferably, the outlet 84 extends in a direction of arrow 103 along axis 32 a distance L of 0.51 cm (0.2) inches to permit the nozzle 34 to engage the opening 42 of container 16 (see Figure 2). Referring now to Figure 4, the toner filling assisting apparatus 10 is shown engaged with toner container 16. As shown in Figure 4, the nozzle 34 is immersed into the toner container 16 through opening 42 therein. The deflector 100 is located within chamber 106 of the container 16. The deflector 100 serves to deflect the powder 12 within the container 16 to provide an area of airborne toner 108 in the upper portion of the container. As the airborne toner 108 settles, settled toner 110 forms uniformly within the container 16 assuring a thorough filling of the container 16. Referring now to Figures 5 and 6, the advantage of utilizing the deflector 100 is shown. In Figure 5, the nozzle 34 is shown without the deflector 100 in place. The nozzle 34 directs the powder 12 into a pile centered along nozzle centerline 32. As can be appreciated from Figure 5, an air gap 112 is formed within the cartridge 16 creating a partially filled toner container 16. Referring now to Figure 6, the nozzle 34 is shown with the deflector 100 secured therein. The deflector 100 serves to scatter the toner into airborne toner 108 which settles into settled toner 110 which is evenly dispersed within the toner container 16. Referring now to Figure 7, an embodiment of the nozzle according to the present invention is shown as nozzle 334. Nozzle 334 is secured to conduit 336 and extends downwardly therefrom. Conduit 336 is similar to conduit 36 of Figures 1-5. Auger 340 is preferably rotatably fitted within conduit 336. Auger 340 is similar to auger 40 of Figures 1-5. As shown in Figure 7, the nozzle 334 extends downwardly from the conduit 336. The nozzle 334 includes a tapered portion 390 which has a generally conofrustrical hollow shape. The tapered portion 390 as shown in Figure 7 has a concave or bowl type shape. It should be appreciated that the tapered portion 390 may likewise have convex or a neutral shape. The tapered portion 390 has a diameter DNI at nozzle inlet 382 and a diameter DNO at the nozzle outlet 384 which is smaller than the nozzle inlet diameter DNI. The nozzle 334 as shown in Figure 7 is made of a porous material. The nozzle 334 may be made of any suitable durable material e.g. a porous plastic material. Such a porous plastic material is available from Porex Technologies Corporation, Fairburn, Georgia, USA and is sold as Porex® porous plastics. The use of high density polyethylene with a pore size of approximately 20 microns is suited for this application. To assist in the flow of the toner 12 and to avoid coating the inner periphery 392 of the nozzle 334 with a coating which may tend to wear quickly, the nozzle 334 includes a boundary layer of flowing air 332 located internally of inner periphery 392 of the nozzle 334. The boundary layer of flowing air 334 may be accomplished in any suitable manner. For example, as shown in Figure 7, the nozzle 334 is surrounded by a housing 330. The housing 330 is secured to the conduit 336 and to the bottom portion of the nozzle 334. The housing 330 thus forms an external cavity 362 between the housing 330 and nozzle 334. Preferably, the external cavity 362 is connected to a compressed air source 364 whereby compressed air is forced through the porous nozzle 334. The compressed air source 364 thus serves to provide the boundary layer of flowing air 332 between the nozzle 334 and the powder 12. The compressed air source may include a valve (not shown) to regulate the amount of air in order to form a proper boundary layer of flowing air 332 to optimize the flow of toner 12 through the nozzle 334. By providing a high speed nozzle with a diameter ratio at the inlet and outlet of the nozzle which are chosen to optimize flow within the nozzle, a nozzle may be provided which optimizes flow within the nozzle. By providing a high speed filling nozzle with an inner periphery with a coating of low friction material, the flow within the nozzle may be maximized. By providing according to the invention a boundary layer of air between the inner periphery of a nozzle and the toner flowing therethrough, the flow of toner within the nozzle may be maximized. By providing a deflector at the outlet of a nozzle, the flow of powder through the nozzle may be evenly dispersed into a container such that the container may be more completely filled and so that voids may not be present within a container. By providing a high speed nozzle including a tapered auger positioned therein, the flow of toner through the auger may be maximized and, at the same time, control of the amount of powder dispensed, normally referred to as the fill weight, may be maximized. By providing a high speed nozzle including a porous material, the flow within the nozzle may be maximized by providing a layer of air to reduce the friction between the nozzle and the powder. In recapitulation, a high speed toner filler for developer material has been described as an improved method for maximizing toner flow for filling toner containers with small apertures. This method allows toner to be moved more accurately and rapidly than prior art systems and also insures that the toner container is filled quickly, completely and cleanly.

Claims: An apparatus (10) for assisting in filling a container (16) from a hopper (14) containing a supply of powder (12), the apparatus comprising: a conduit (36) operably connected to the hopper (14) and extending downwardly therefrom, said conduit (36) adapted to permit a flow of powder (12) therewithin; a nozzle (34) operably connected to the conduit (36) and extending downwardly therefrom, said nozzle (34) defining an inlet (82) thereof for receiving powder (12) from the conduit (36) and defining an outlet (84) thereof for dispensing powder (12) from the nozzle (34) to the container (16), the inlet (82) defining an inlet cross sectional area perpendicular to the flow of the powder (12) and the outlet defining an outlet cross sectional area perpendicular to the flow the powder (12), the inlet cross sectional area being larger than the outlet cross sectional area; and a conveyor (40) located at least partially within said conduit (36), the conveyor (40) assisting to provide the flow of powder (12) to the container (16), characterized by said nozzle (34) defining an inner periphery (392) thereof; and further comprising means (364) for providing a layer (332) of air between said inner periphery (392) and the flow of powder (12) wherein the flow of powder through said nozzle (341,334) is enhanced. The apparatus of claim 1, further comprising a deflector (100) operably associated with said nozzle (34) for deflecting the powder (12) as it exits said nozzle (34). The apparatus as claimed in claim 1, wherein said nozzle (34) defines an inner surface thereof, at least a portion (90) of said inner surface being coated with a material (94) having a surface with a coefficient of friction of less than 0.25. The apparatus as claimed in claim 1, wherein said deflector (100) comprises a blade attached to said conveyor (40). The apparatus as claimed in any of the claims 1 to 4, further comprising a tray (61) positionable between said nozzle (34) and the container (16) for collecting powder when the nozzle (34) is spaced from the container (16). The apparatus as claimed in any of the claims 1 to 5, wherein at least a portion of said nozzle (34) has a hollow, substantially conofrustrical shape, the hollow conofrustrical portion defining a cavity therein. The apparatus as claimed in claim 6, wherein said conveyor (40) is spaced from the cavity. The apparatus as claimed in claim 6, wherein a portion of said conveyor (40) is spaced within the cavity, wherein the conveyor (40) assists the flow of powder (12) through said nozzle (34) . The apparatus as claimed in claim 7, wherein said conveyor comprises an auger; and wherein said auger closely conforms to said conduit. The apparatus as claimed in any of the claims 1 to 6, wherein the hollow, substantially conofrustrical portion of said nozzle (34) defines an outer periphery thereof, the outer periphery defining an included angle of approximately 20 degrees.

Inventors: BARBISAN JOSEPH C, HIGUCHI FUMII, WEGMAN PAUL M, ZELAZNY JOSEPH S, BARBISAN, JOSEPH C., HIGUCHI, FUMII, WEGMAN, PAUL M., ZELAZNY, JOSEPH S.
Applicants: XEROX CORP, XEROX CORPORATION
Application year: 1998
Main classification: B65B39
IPC codes: G03G15, B65B1, B65B39