Abstract:
A toner cartridge has a base and a slide slidably received in a slot of the base with at least one opening therein. A rotatable knob is inserted into the slide opening, wherein knob rotation results in a portion of the knob contacting a slide opening, thus moving the slide with respect to the base to one of a fully opened and fully closed position. The knob can include an eccentric cam which engages the slide opening to cause slide movement. The knob can have an axle which engages an opening in the base. The knob also can have a plurality of teeth on an outer edge thereof. The slide opening can have teeth which engage the teeth of the knob to move the slide with respect to the base.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Serial No. 60/301,570, filed on Jun. 27, 2001. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates to a toner cartridge or cassette for supplying toner to the developing device of an image forming apparatus such as an electrostatic copying apparatus or the like. 
     Generally, a toner cartridge has a hopper area for storing a predetermined supply of toner and is provided with a toner flow or outlet region disposed in the bottom area thereof. Removable closure or seal means is provided to open the toner flow or outlet region when and as desired to facilitate toner flow into an associated copy machine. The closures or seals typically employed include thin flexible strips, seal tape, shiftable shutters and the like. 
     Replacement toner cartridges are desirably first installed in a closed condition in an associated image forming apparatus. The closure or seal member may then be opened or removed to allow toner in the hopper area to flow outwardly from the cartridge into the image-forming apparatus for use. In some cases, the cartridge remains in place on the apparatus while in other cases the cartridge is immediately removed. This really is a function of the apparatus design and operational parameters. 
     In either situation, it is important to be able to re-close the toner flow or outlet region during cartridge removal to prevent unacceptable and undesired toner spills. That is, a small amount of residual toner may remain in the cartridge even though the cartridge may be considered empty from an operational point of view. Thus, it is highly desirable to have effective and reliable means to re-close the cartridge to avoid toner spillage during cartridge removal. Toner is comprised of very small particles which, if undesirably released, can create a dirty work environment and cause operational and quality difficulties in the image forming apparatus itself. 
     Some existing toner cartridges have toner flow or outlet openings which can be closed by a plate-like cover prior to removal of the cartridge. However, the covers are sometimes rather loose fitting so that some residual toner can still escape into the air and onto the imaging apparatus. Some other existing cartridges use selectively shiftable shutter mechanisms to open and close toner flow. There, however, it is oftentimes difficult for the user to determine whether the shutter is completely or partially open or closed before lifting or removing the toner cartridge from the image-forming apparatus. This, too, presents the potential for unknowingly spilling residual toner. Moreover, if the plate-like covers or shutters are dimensioned to be close fitting with the associated cartridge to prevent spillage, they may be very difficult to open and close. This, in turn, creates an entirely different set of problems. 
     Accordingly, it has been considered desirable to develop an improved toner cassette which would overcome the foregoing difficulties and others while providing better and more advantageous overall results. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention relates to a toner cartridge or cassette having a louvered slide mechanism which may be selectively opened and closed for allowing or blocking toner flow therefrom. The present invention provides a mechanical arrangement for allowing the user to know when the cartridge is open or closed, and has the added advantage of providing a mechanical advantage over existing slide mechanisms to effect ease of opening and closing. 
     Current louvered slide mechanisms do not indicate if the cartridge is open (allowing toner to drop from the bottom) or closed. One aspect of the invention is to indicate to the end user that the cartridge is fully open or closed. Also, existing toner cartridges have slides and slide mechanisms which are oftentimes difficult to move by hand pulling or pushing. The present invention provides an eccentric knob or cam which provides a mechanical advantage to the opening and closing process. 
     More particularly, the present invention relates to a toner cartridge having a hopper with a bottom wall with at least one outlet opening in the bottom wall. A base receives the hopper and also has at least one outlet opening therein and a slot extending from a first end to a second end. A slide is slidably received in the slot of the base and also has at least one outlet opening therein. A loading tray can be provided which has a slot in which the base is received within the slot. 
     A rotatable knob or movable member is inserted into a second opening in the slide, wherein rotation of the knob results in a portion of the knob contacting the second opening of the slide, thus moving the slide with respect to the base and the hopper in a linear fashion to one of a fully opened and fully closed position. In a fully opened position, each outlet opening of the hopper, base and slide is in registry, allowing toner to flow out of the hopper to an image forming apparatus. In a fully closed position, each outlet opening of the slide is not in registry with the hopper and base openings, thus preventing toner flow out of the hopper. 
     The knob has a first surface having a handle and a second surface having an eccentric cam and an opening. A pin is inserted through a hole of the base and engages the opening of the knob. The eccentric cam engages the side wall of an opening of the slide to cause the slide to move with respect to the base. This slide opening can be rectangular or square. Labels can be provided on the slide to indicate the fully opened and fully closed positions. 
     The knob can have an eccentric cam and an axle, instead of a separate pin, where the axle engages the hole of the base. The knob can further have a plurality of teeth around an outside edge thereof. The slide can include an elongated opening with a plurality of teeth on an inner wall thereof. The teeth of the knob would matingly engage the teeth of the slide and rotation of the knob results in engagement of the teeth which in turn moves the slide with respect to the base. This rack and pinion arrangement allows a greater range of movement of the slide. 
     One advantage of the present invention is found in the provision of an indicator to the user that the cartridge is fully opened or closed. 
     Another advantage of the invention resides in the provision of a device for adding a mechanical advantage to the louvered slide mechanism for making it easier to open and close a cartridge. 
     Yet another advantage of the invention resides in the provision of a knob with a rack and pinion arrangement to provide a large range of movement. 
     Still other advantages and benefits of the invention will become apparent to those skilled in the art upon a reading and understanding of the following detailed description. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention may take form in certain parts and arrangements of parts, preferred embodiments of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein: 
     FIG. 1 shows an exploded side elevational view of the toner cartridge with a mechanical advantage mechanism found in a preferred embodiment in accordance with the present invention; 
     FIG. 2 shows a bottom elevational view of a gasket of the toner cartridge of FIG. 1; 
     FIG. 3 shows a top elevational view of a slide of the toner cartridge of FIG. 1; 
     FIG. 4 shows a top elevational view of the base of the toner cartridge of FIG. 1; 
     FIG. 5 shows a top elevational view of a load tray for the toner cartridge of FIG. 1; 
     FIG. 6 shows a bottom elevational view and a side elevational view of a hopper of the toner cartridge of FIG. 1; 
     FIG. 7 shows a top, side and bottom elevational view of an eccentric cam knob of the toner cartridge of FIG. 1; 
     FIG. 7A shows a top elevational view of the eccentric knob installed on the slide of the toner cartridge of FIG. 1; 
     FIG. 8 is an exploded perspective view of the toner cartridge with a mechanical advantage mechanism formed in accordance with a second preferred embodiment of the present invention; 
     FIG. 9 shows a perspective view of the assembled toner cartridge of FIG. 8; 
     FIG. 10 is an exploded perspective view of the toner cartridge with a mechanical advantage mechanism formed in accordance with a third preferred embodiment of the present invention; and, 
     FIG. 11 is an enlarged top view of a slide and knob assembly of the toner cartridge of FIG.  10 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the drawings wherein the showings are for the purposes of illustrating the preferred embodiments of the invention only and not for purposes of limiting same, FIG. 1 shows an exploded side elevational view of the toner cassette formed in accordance with the first preferred embodiment of the present invention. 
     Referring to FIGS. 1 and 6, the cassette has a hopper  10  with a series of outlet openings or windows  12  spaced longitudinally along the bottom wall thereof. This hopper may be formed by convenient means such as blow molding, vacuum forming or the like. Openings  12  can be equally spaced apart and are offset at an angle along a longitudinal axis of the hopper as well as along a transverse axis of the hopper. The openings can also be normal to the longitudinal axis and transverse axis. 
     Referring to FIGS. 1 and 2, a flexible gasket  14  having a series of through or outlet openings  16  to match those in the bottom of the hopper is affixed to the hopper  10  by removing a silicon paper or similar covering and positioning the gasket to align the openings  12 ,  16  in registry with an adhesive side of the gasket toward the hopper. The gasket is firmly pressed against the hopper bottom. The gasket  14  can be made from polyurethane foam or other suitable material as may be desired. 
     Referring to FIGS. 1,  3  and  4 , a molded plastic louvered slide  18  is received in a slot in a base  20 . The slide  18  has window or outlet openings  22  spaced equally apart or in a manner so that when the slide is fully inserted or slid into the base, the window openings are aligned with openings  24  of the base to allow toner flow in a manner to be described. The slide has a rectangular-shaped cam hole  26  which is positioned over a round hole  28  in the base. The cam hole  26  could also be of a different configuration, such as a round hole. 
     The toner storage hopper  10  is installed onto base  20  by aligning the openings  12  with openings  24  in the base and firmly seating the hopper onto the base. Eight clips  30  on the base align with and engage top surfaces of corresponding ribs  32  on the hopper to firmly hold the hopper onto the base. 
     Referring to FIG. 1, a lid  34  is welded or fixed into position in the top of the hopper. Ribs  36  on the lid are aligned with channels  38  on the top of the hopper. A fill hole  40  is located on a side of the hopper for filling the hopper with toner. When the hopper is installed on the base, the fill hole  40  is on a side opposite to a side adjacent the opening  28  in the base. A cap plug  42  is shipped separately with the hopper. The plug is installed into hole  40  after the hopper is filled with toner. Other toner hopper shapes and assembly techniques may also be used to accommodate a variety of different applications. 
     Referring to FIGS. 1 and 5, a load tray  50  is slid over the bottom of the base. Flanged edges  52  of the base serves as alignment slots for the load tray. An arrow  54  on the load tray is to be located on the same side as the hole  28  in the base. 
     With reference again to FIG. 1, an axle pin  60  is inserted through the bottom of the base  20  and through hole  28  and seated in a counterbore  62  of the pin with a small diameter  64  extending through hole  28  and hole  26 . 
     Referring to FIGS. 1,  7  and  7 A, an eccentric knob  66  is aligned with pin  60  and mounted onto the pin by aligning a hole  68  in the knob with the top of the pin and pressing the knob onto the pin until the knob bottoms out on a shoulder of the pin. 
     An eccentric cam  70  is fully positioned within the cam hole  26  on the slide  18 . The eccentric cam is rotatable in hole  26  so that the cam surface will engage the side wall of the hole. This cooperating action will cause the slide to shift or slide relative to the base so that window openings  24 ,  22  and  12  of the base, slide and hopper, respectively, are moved toward registry; therefore, allowing toner to freely flow into the image-forming apparatus as the knob assembly is rotated 90° or 180° to the open position. The eccentric cam adds a mechanical advantage thus rendering it far easier for the user to open and close the slide. 
     Referring to FIGS. 7 and 7A, an arrow  72  on the knob points toward the hopper  10  and away from a “OPEN” label  74  on the base when installed. The “OPEN” label along with a “CLOSED” label  76  on the slide indicate to the user whether the slide is in the open or closed position. This, in turn, enables the user to avoid undesired toner spilling when removing the toner cartridge from the image forming apparatus. 
     The knob is manually rotated via a handle  78 . When the knob is rotated clockwise to the open position, as indicated by arrow  80  on the knob, the slide  18  moves inwardly, thus aligning the openings  12 ,  22  and  24  and exposing the “OPEN” label  74  on the base and covering the “CLOSED” label  76  on the slide. When the knob is rotated counterclockwise to the closed position, as indicated by arrow  82  on the knob, the slide moves outwardly, moving the windows  12 ,  22  and  24  out of registry, thus blocking flow of toner out of the hopper. The “OPEN” label is covered by the slide, and the “CLOSED” label on the slide is exposed. 
     While the invention has been described with slide  18  fully inserted into base  20  when the hopper is opened, it would also be possible to construct the cartridge so that the slide would be moved to the fully inserted position in the base to close the hopper. The cam assembly could also be advantageously employed in this modified construction. 
     Referring now to FIGS. 8 and 9, a cassette in accordance with a second preferred embodiment is shown. The cassette has a base  110  with a series of openings or windows  112  spaced longitudinally along the bottom wall thereof. A flexible gasket  114  having a series of through openings  116  to match those in base  110  is adhesively secured to the inside or top surface of the base so that openings  112 ,  116  are disposed in registry. The gasket  114  can be made from polyurethane foam or other suitable material as may be desired. 
     A molded plastic louvered slide  118  is received in a slot  120  in the base. The slide  118  has window openings  122  spaced in a manner so that when the slide is fully inserted or slid into the base, the window openings are aligned with the closed sections of the base intermediate openings  112  to close and seal the cartridge for preventing toner flow. 
     A toner storage hopper  130  is provided for installation onto base  110 . This hopper may be formed by convenient means such as blow molding, vacuum forming or the like, and includes a gasket receiving groove  132  formed peripherally around the bottom edge thereof. Groove  132  closely receives a hopper seal gasket  134  of a suitable type and material. This hopper assembly is snapped onto base  110  and retained firmly in place by a series of snap hook fingers  136  integrally molded into the base. Other toner hopper shapes and assembly techniques may also be used to accommodate a variety of different applications. 
     With continuing reference to both FIGS. 8 and 9, an eccentric cam assembly  140  has an axle  142  inserted through a hole  144  in the slide, and locks into a hole  146  in base  110 . Axle  142  is rotatably received in hole  146  and is prevented from removal by a lock tab, a headed pin or by other convenient means. An eccentric cam disposed at the base of the knob assembly is rotatable in hole  144  of slide  118  so that the cam surface will engage the side wall of the hole. This cooperating action will cause the slide to shift relative to base  110  so that window openings  112 ,  122  are moved toward registry, thereby allowing toner to freely flow into the image forming apparatus as the knob assembly is rotated either 90° or 180°. The eccentric cam adds a mechanical advantage thus rendering it far easier for the user to open and close the slide. 
     Referring to FIG. 9, the cam has a “tick” mark  150  so that the open and closed positions can be indicated by markings or indicia  152  on the top surface of the slide. The open and closed positions can be 90° or 180° apart. Thus, the “tick” mark  150  and the markings  152  indicate to the user whether the slide is in the open or closed position. This, in turn, enables the user to avoid undesired toner spilling when removing the toner cartridge from the image forming apparatus. 
     While the invention has been described with slide  118  fully inserted into base  110  when the hopper is closed, it would also be possible to construct the cartridge so that the slide would be moved to the fully inserted position in the base to open the hopper. The cam assembly could also be advantageously employed in this modified construction. 
     Referring now to FIGS. 10 and 11, a cassette in accordance with a third embodiment is shown. The cassette has a base  200  with a series of openings or windows  202  spaced longitudinally along the bottom wall thereof. A flexible gasket  204  having a series of through openings  206  to match those in the base  200  is adhesively secured to the inside of top surface of the base so that openings  202 ,  206  are disposed in registry. The gasket  204  can be made from polyurethane foam or other suitable material as may be desired. 
     A molded plastic louvered slide  210  is received in a slot  220  in the base. Slide  210  has window openings  222  spaced equally apart or in a manner so that when the slide is fully inserted or slid into the base, the window openings are aligned with the closed sections of the base intermediate opening  202  to close and seal the cartridge for preventing toner flow. 
     A toner hopper  230  is provided for installation onto base  200 . This hopper may be formed by convenient means such as blow molding, vacuum forming or the like, and includes a gasket receiving groove  232  formed peripherally around the bottom edge thereof. Groove  232  closely receives a hopper seal gasket  234 . 
     The hopper assembly is snapped onto base  200  and retained firmly in place by a series of snap hook fingers  236  integrally molded into the base, or by other suitable fastening means. 
     With continued reference to both FIGS. 10 and 11, a knob  250  has an axle  242 , made of metal or another suitable material, which is inserted through a hole  252  in the slide and a corresponding hole  246  in base  200 . Axle  242  is rotatably received in hole  246  and is prevented from removal by a lock tab, a headed pin or by other convenient means. 
     The knob has gear teeth  248  around the circumference or outside edge of the knob. In the preferred, embodiment, spur gear teeth are used; however, other gear teeth arrangements could be used as well. The knob is received in elongated slot or opening  252  in the slide which has an internal rack with gear teeth  254  along straight portions of the slot. Together teeth  248  and  254  form a rack and pinion assembly in which teeth  248  of the knob engage teeth  254  of the slot. This cooperating action causes the slide to slide or shift in a linear fashion relative to base  200  so that window openings  202 ,  206  are moved toward registry, thereby allowing toner to freely flow into the image forming apparatus. The gear teeth of the knob and the slide elongated slot permit a larger range of movement of the slide than the eccentric cam knob. 
     The knob can have a “tick” mark  260  which indicates open and closed positions when aligned with markings or indicia similar to indicia  152  shown in FIG.  9 . 
     The invention has been described with reference to three preferred embodiments. Obviously, alterations and modifications will occur to others upon a reading and understanding of this specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.