Patent Publication Number: US-6666240-B2

Title: Toner feeding container and powder feeding container

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to a toner feeding container and powder feeding container that refill toner in a toner cartridge installed for apparatuses such as copiers and multi-functional printers. 
     2. Description of Related Art 
     Hereafter, a toner feeding container is used as an example to illustrate this type of powder feeding container. For apparatuses such as copiers and multi-functional printers that install toner cartridges with toner refill functions, a service person needs to refill toner in a toner cartridge when the toner in the toner cartridge runs out. 
     Conventionally, a toner feeding container that is used for refilling toner is made from plastic material. For example, as shown in FIG. 8, the container is configured with container  801  that has a function to contain toner, and funnel  802  that has a function to pour toner into a toner cartridge. Container  801  has a cylindrical form to which funnel  802  is fully attached, narrowly stretching into small opening  803  formed at the extremity. 
     When refilling toner, the above-described toner is used as follows. First, a service person brings a toner feeding container to a user who has a copier or the like, having no remaining toner. Then, the service person takes out a toner cartridge with no toner from the copier. He/she releases opening  803  by removing a cap fitted to funnel  802  of the toner feeding container. Then, he/she turns over the toner feeder container upside down, fits opening  803  of the toner feeding container to an opening ( 805  of FIG. 8) for toner refill, and drops the toner into toner cartridge  804 . After finishing the toner refill into toner cartridge  804 , he/she takes back the empty toner feeding container. 
     However, the conventional toner feeding container had the following problem. 
     The conventional toner feeding container has only one opening  803  at the extremity of funnel  802 , and the toner feeding container is turned upside down so that opening  803  is faced down and the toner flows from opening  803 . Therefore, during the toner flow, the toner is compressed at the bottom of the toner feeding container. Furthermore, funnel  802  is narrowed toward opening  803 . Thus, the toner becomes compressed around opening  803 , thereby increasing the internal pressure. This clogs the toner, preventing the toner from easily flowing outward. 
     Therefore, the service person is required to perform a very bothersome task such as either squeezing the toner feeding container to drop the toner, or removing the toner feeding container from toner cartridge  804  to hit the container on a nearby desk, or the like, facing the opening  803  upward, so that the toner clogged around opening  803  is broken down. Then, the service person has to turn the container upside down again, to fit the container back into toner cartridge  804 . 
     The toner feeding cartridge is not fixed inside of the apparatus but is collected after the toner is transferred into the toner cartridge as it is no longer needed. However, since the toner feeding container is made from plastic, it is impossible to fold the container into a small size even if it is empty. Thus, only the same number of toner feeding containers as full containers can be fit in a delivery case. Therefore, it is impossible to cut the delivery cost after the containers are emptied, creating unnecessary costs. 
     Furthermore, as described above, a toner feeding container is no longer of use after the toner is refilled into the toner cartridge. Nevertheless, the plastic toner feeding container becomes a waste of resources since it is disposed after a refill. 
     Moreover, when toner is refilled with the above toner feeding container for the entire copiers and multifunctional printers across the country, an enormous amount of trash will be generated every year thus creating a severe adverse impact to the environment. 
     SUMMARY OF THE INVENTION 
     This invention is provided to address the above-described problems. The purpose of the present invention is to provide a toner feeding container and powder feeding container that can simplify the powder (e.g., toner) refill process, decreasing the delivery cost after the toner feeding container is used for refill, and is environmentally friendly. 
     The powder feeding container according to the present invention is made from paper, resin film, or a synthetic film made with paper and resin film, the container containing powder within, and having a peak at one end, which is formed from an incline that starts from a middle of one edge of the container. The peak end is cut to form a first opening that releases the inside powder, whereas a change proximity area that starts forming an inclined edge is cut, and the rear area from the incision is folded inward, so that air is sent into the first opening along the inner wall of the inclined edge, forming a second opening. 
     According to the present invention, air is sent into the first opening from the second opening along the inner wall of the inclined edge, while controlling the amount of powder that flows into the first opening by an inner wall of an incline formed by the folded-in portion in to the inner body, preventing a sudden influx of powder flowing into the first opening. Therefore, it is possible to prevent the powder from becoming compressed around the first opening by restricting the powder outflow, and prevent the increasing inner pressure of the powder by allowing the airflow. Since the powder flow is maintained, it is possible to securely prevent the powder from becoming solid around the first opening and clogging the first opening, and smoothly eject the powder. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention is further described in the detailed description which follows, with reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention, in which like reference numerals represent similar parts throughout the several views of the drawings, and wherein: 
     FIG. 1 is a side view illustrating a configuration of a toner feeding container according to an embodiment of the present invention; 
     FIG. 2 illustrates a procedure for the toner feeding container according to the embodiment of the present invention prior to refilling toner; 
     FIG. 3 illustrates a shape obtained from the procedure for the toner feeding container according to the embodiment of the present invention prior to refilling toner; 
     FIG. 4 illustrates a toner refill procedure using the toner feeding container according to the embodiment of the present invention; 
     FIG. 5 illustrates a toner and air flow during the toner refill by the toner feeding container according to the embodiment of the present invention; 
     FIG. 6 is a side cross sectional view of the toner feeding container during the toner refill according to the embodiment of the present invention; 
     FIG.  7 ( a ) illustrates the toner feeding container according to the embodiment of the present invention, having only a partial folded-in rear area from an incision, instead of having the entire folded-in rear area from the incision; 
     FIG.  7 ( b ) illustrates a first opening of the toner feeding container according to the embodiment of the present invention, which is formed below an extended line from an inclined surface of an inner wall; and 
     FIG. 8 illustrates a toner refill procedure of a conventional toner feeding container. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The embodiment of the present invention are explained in the following, in reference to the above-described drawings. A toner feeding container is used as an example of powder feeding container in order to illustrate in this embodiment. 
     FIG. 1 is a side view illustrating a configuration of toner feeding container  100  according to an embodiment of the present invention. 
     Toner feeding container  100  is made from paper, resin film, or a synthetic film made with paper and resin film (hereafter referred to as “paper”), inside of which contains the toner for a refill. 
     Specifically, paper that is cut into a predetermined shape is folded to form a bottom edge ( 102 ) in the center as shown in FIG.  1 . After containing toner inside, toner feeding container  100  is configured by sealing the open surroundings of the paper. In FIG. 1, shaded areas illustrate parts that are sealed. 
     As shown in FIG. 1, toner feeding container (body)  100  has a peak at one end that provides a smooth toner refill into a toner cartridge, which is removed from a copier. Hereafter, this peak-shaped end is referred to as a front end of toner feeding container  100 , while the other end is referred to as rear end. 
     In particular, toner feeding container  100  includes upper edge  101  and lower edge  102  in mutually parallel positions from the rear end of toner feeding container  100 , when it is viewed from a side. Upper edge  101  is shorter than lower edge  102 . Toner feeding container  100  also has inclined edge  103  that connects one end of upper edge  101  and lower edge  102  at the front end side. With inclined edge  103  that stretches from upper edge  101  to lower edge  102 , toner feeding container  100  forms a peak at the front end. 
     On one side of toner feeding container  100 , cutting lines and a folding line are printed at predetermined locations. In particular, three cutting lines and one folding line are printed. 
     Cutting line  104  is printed at a predetermined location around the front end of toner feeding container  100 , having a vertical line from lower edge  102  stretching upward. Printed cutting line  104  ends where it reaches inclined edge  103 . 
     Cutting lines  105  and  105 ′ are printed from one end of upper edge  101  that faces the front end of toner feeding container  100 , stretching toward lower edge  102  at the rear end of toner feeding container  100 . The angle formed between cutting line  105  and inclined edge  103  is roughly 90 degrees. Cutting lines  105  and  105 ′ are printed up to the middle of toner feeding container  100 . 
     It is not necessary to print cutting line  105  from the end of upper edge  101  that faces the front end of toner feeding container  100 , as long as the line is printed at a change proximity area of upper edge  101  and inclined edge  103 . 
     The folding line  106  is printed so as to connect end proximity of upper edge  101  that faces the rear end of toner feeding container  100 , and one end of cutting line  105 . More specifically, folding line  106  is at the rear side of toner feeding container  100 , having line that starts where the sealing portion formed on the upper edge  101  and the sealing portion formed on the rear side edge of toner feeding container  100  meet inward, stretching toward the inner end of cutting line  105 . 
     In the example shown in FIG. 1, cutting lines  104  and  105  and folding line  106  are printed with dotted lines and alternate long and short dotted line. However, such lines can also be printed as “cutting line”, “folding line”, etc., so that the person who handles the container (service person from the manufacturer) can easily identify them. 
     When a toner refill is needed, a service person performs a following procedure on toner feeding container  100  with the above-described configuration. FIG. 2 illustrates a procedure for toner feeding container  100  prior to refilling toner. 
     In the procedure prior to refilling toner, the service person cuts off the front end side along cutting line  104 . Accordingly, first opening  201  that ejects the toner from toner feeding container  100  into a cartridge is formed. 
     Then, the service person makes two incisions along cutting lines  105  and  105 ′. Accordingly, the area above cutting line  105  facing the rear end can freely be folded. The reason for having two cutting lines  105  and  105 ′ is that, when only cutting line  105  is provided for inwardly folding the area above cutting line  105  facing the rear end, it is difficult to fold the area inward because the front end of the area can become trapped. Therefore, having two cutting lines  105  and  105 ′ creates a clearance that simplifies the folding step. However, as long as folding step is not complicated, there is no harm having only one cutting line  105  for the incision. 
     Finally, the service person folds in the rear end area of toner feeding container  100 , which starts from where the incisions were made along cutting lines  105  and  105 ′ (i.e., the upper edge  101  area) into the inside of toner feeding container  100 , along folding line  106 . Accordingly, the rear end of toner feeding container  100 , after the incisions along cutting lines  105  and  105 ′ were made, is released, and second opening  202  that sends air into first opening  201  is created. 
     Additionally, upon performing the above procedure prior to refilling toner, the service person is required to raise the front end of toner feeding container  100  upward, or hold the front end with fingers, when facing downward, to make the incision, so that the toner contained inside does not leak outside. 
     FIG. 3 illustrates a shape of toner feeding container  100  obtained from the above procedure. 
     As shown in FIG. 3, toner feeding container  100  has first opening  201 , which ejects toner, at a proximity of lower end of inclined edge  103  by the procedure performed by the service person prior to refilling the toner. Second opening  202 , which sends air into first opening  201 , is also formed at proximity of upper end of inclined edge  103 . 
     Inner wall  301  of the upper side of toner feeding container  100  is also created when the back side of upper edge  101  is folded inside of toner feeding container  100 . This inner wall  301  has an incline that starts from the upper rear end of toner feeding container  100  stretching toward first opening  201 . The relationship between the incline of inner wall  301  and first opening  201  is later described. 
     As shown in FIG. 4, the service person performs the toner refill procedure using toner feeding container  100  that is configured as described above. Specifically, opening  401  of toner cartridge  400  that is removed from the copier is fitted with first opening  201  of toner feeding container  100 . Next, the rear end of toner feeding container  100  is gradually raised upward. The service person may raise the rear end of toner feeding container  100  up to an angle where the toner inside should not completely block first opening  201 . 
     FIG. 5 illustrates a toner and air flow during the toner refill by toner feeding container  100 . 
     As shown in FIG. 5, when the rear end of toner feeding container  100  is raised while first opening  201  is fixed, the toner inside moves to first opening  201  and ejects from first opening  201 . Air is also sent from second opening  202 , and flows through the upper area of toner being ejected from first opening  201 . This air that flows from second opening  202  reduces the increasing inner pressure of the toner in toner feeding container  100 . Accordingly, the flow of the toner is maintained. 
     Additionally, upon refilling the toner, the toner delivery space is controlled by inner wall  301  inside of toner feeding container  100 . Accordingly, toner will not leak out from second opening  202 . 
     FIG. 6 is a side cross sectional view for refilling toner in toner feeding container  100 . 
     As shown in FIG. 6, the entire rear area of the incision that is formed by the incision at cut line  105  is folded inside of toner feeding container  100 . Fist opening  201  is formed at a location that includes an area above an extended line from the inclined surface of inner wall  301 , which is formed inside of toner feeding container  100  by folding in the above-described area. 
     FIG. 7 is used to illustrate the reasons for having the folded-in area at the entire rear area from the incision in toner feeding container  100 , and for having first opening  201  formed at the location that includes the area above the extended line from the inclined surface of inner wall  301 . 
     First, FIG.  7 ( a ) is used to illustrate the reason for having the folded-in area at the entire rear area from the incision in toner feeding container  100 . 
     FIG.  7 ( a ) illustrates toner feeding container  100  having only a partial folded-in rear area from the incision, instead of having the entire folded-in rear area from the incision. 
     As illustrated in FIG.  7 ( a ), when toner feeding container  100  has only a partial folded-in rear area from the incision, the toner that is kept in the rear area of toner feeding container  100  will suddenly have a compressed delivery space by inner wall  301  when approaching first opening  201 . Accordingly, the toner is excessively compressed and increases its inner pressure at the lower area of inner wall  301 , which generates the clogging of toner. Therefore, the toner can no longer flow smoothly. 
     Because of the above-described problem, toner feeding container  100  of the present invention has the entire rear area from the incision that are folded inward. Accordingly, the toner that is contained in the rear area of the container does not suddenly have a compressed delivery space, when approaching first opening  201 , but is gradually narrowed down. Therefore, by averting an excessively narrowed area for the toner, it is possible to prevent clogging of toner, thus further maintaining a smooth flow of the toner. 
     However, even when toner feeding container  100  having only a partial folded-in rear area from the incision is employed, as shown in FIG.  7 ( a ), toner flow is much smoother than that of a conventional plastic toner feeding container. 
     The following illustrates the reason for having first opening  201  formed at the location that includes the area above the extended line from the inclined surface of inner wall  301  by referring to FIG.  7 ( b ). 
     FIG.  7 ( b ) illustrates first opening  201  that is formed below the extended line from the inclined surface of inner wall  301 . 
     As shown in FIG.  7 ( b ), when the entire rear area from the incision is folded inside of toner feeding container  100 , and when first opening  201  is formed below the extended line from the inclined surface of inner wall  301 , toner that flows along the inclined wall may reach the upper part of first opening  201  and close first opening  201 , interfering the airflow from second opening  202 . Therefore, toner becomes clogged because of the increased inner pressure of toner within toner feeding container  100 , and the toner can no longer flow smoothly. 
     Accordingly, toner feeding container  100  has first opening  201  formed at the location that includes the area above the extended line from the inclined surface of inner wall  301 , when the entire rear area from the incision is folded inside of toner feeding container  100 . Therefore, it is possible to prevent the toner, which flows along the inclined surface of inner wall  301 , from reaching the upper area of first opening  201  and closes the first opening  201 . Simultaneously, it is possible to allow airflow from second opening  202 , thereby releasing the inner pressure of toner around first opening  201  and preventing the clogging of toner. Accordingly, it is possible to further maintain the smooth flow of toner. 
     However, even when toner feeding container  100 , having first opening  201  that is formed below the extended line from the inclined surface of inner wall  301 , is employed, as shown in FIG.  7 ( b ), toner flow is much smoother than that of a conventional plastic toner feeding container. 
     Accordingly, toner feeding container  100  of the present invention includes an incision at the extremity at upper edge  101  and forms second opening  202  when the entire rear area from the incision is folded in. Therefore, it is possible to send air from second opening  202  into first opening  201  along the inner area of inclined edge  103 . At the same time, it is possible to control the amount of toner that flows into first opening  201  by inner wall  301  that is formed by the entire area of upper edge  101 , which is folded inside of toner feeding container  100 , thereby preventing a sudden influx of the toner at first opening  201 . Accordingly, it is possible to prevent the compression of toner around first opening  201 . Also, it is possible to control the increasing inner pressure of toner by the airflow, as well as preventing the toner compression around first opening  201  by controlling the toner flow. Since the toner flow is maintained, it is possible to securely prevent the toner from becoming solid around first opening  201  and clogging first opening  201 , and smoothly eject the toner. 
     Also, since toner feeding container  100  is made from paper, resin film, or a synthetic film made with paper and resin film, the service person can easily alter the shape of the container. Therefore, even if there are partial toner clusters in the container, the clusters can be broken down with very little power, instead of intensely squeezing the container or hitting the container on the desk, as it has been conventionally performed. As a result, it is possible to prevent the toner from clogging first opening  201  and to further simplify the toner refill process. 
     Furthermore, since toner feeding container  100  is made from paper, resin film, or a synthetic film made with paper and resin film, the container can be folded down after the toner refill. Accordingly, it is possible to largely increase the number of containers to be collected and fitted back to the delivery case, thereby decreasing the cost of delivery. 
     Additionally, since toner feeding container  100  is made from paper, resin film, or a synthetic film made with paper and resin film, it is possible to reduce the production energy, compared to producing a container with plastic. Thus, it is possible to largely decrease the adverse impact on the environment. 
     In addition, second opening  202  is formed from an incision at the extremity at upper edge  101  and folding in the entire rear area from the incision. Accordingly, it is possible to control the flow of toner that moves to second opening  202  within toner feeding container  100  by inner wall  301  that is formed by the folded-in portion. Therefore, toner leakage from second opening  202  is prevented during the toner refill, even if second opening  202  is provided. Since inner wall  301  prevents the toner leakage from second opening  202 , it is not necessary to have another special configuration for the toner leakage prevention. This simple configuration (inner wall  301 ) can prevent such a toner leakage. 
     In addition, although toner feeding container is employed to illustrate the present invention, this invention can also be widely applied to refilling other powder form materials, e.g., detergent, flour (food), etc., as long as the essential characteristics of the invention is not altered. 
     It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to exemplary embodiments, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular structures, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. 
     The present invention is not limited to the above described embodiments, and various variations and modifications may be possible without departing from the scope of the present invention. 
     This application is based on the Japanese Patent Applications No. 2002-007260 filed on Jan. 16, 2002, and No. 2002-027644 filed on Feb. 5, 2002 entire content of which are expressly incorporated by reference herein.