Patent Publication Number: US-8977145-B2

Title: Detection device for detecting state of waste toner container and image forming apparatus using such detection device

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of the foreign application priority of Taiwan Application No. 101149684, which was filed on Dec. 25, 2012 and is incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a detection device for detecting a state of a waste toner container and an image forming apparatus using such a detection device, and, more particularly, to a detection device for detecting both the presence and loading level of the waste toner container and the image forming apparatus using such a detection device. 
     2. Description of the Prior Art 
     A conventional image forming apparatus detects the loading level of the waste toner container by different ways, such as detecting the optical signals, weight or pressure or the use of other mechanisms. U.S. Pat. No. 4,761,674 discloses a device disposed in the waste toner container, and the device comprises a flexible film with a reflection plate. The reflection plate reflects light to a sensor when the container is full of waste toner. However, the device isn&#39;t able to detect a nearly full state of the waste toner container. A device with an electric balance detecting the weight of the waste toner container is disclosed by U.S. Pat. No. 5,260,755. The device detects the weight of the waste toner and turns the detecting result into an electrical signal, and is able to detect the loading level of the container precisely. But it should be known that the cost of the electric balance is expensive. U.S. Pat. No. 8,380,117 discloses an image forming apparatus with a detecting bar for detecting the loading level. However, the structure of the apparatus is very complicated. 
     In addition, it is also important to detect the presence of the waste toner container. The waste toner will be scattered in the image forming apparatus if the user makes the apparatus print and isn&#39;t aware of the absence of the container. It causes the worse quality of printing and even damages the image forming apparatus. 
     SUMMARY OF THE INVENTION 
     Therefore, an objective of the invention is to provide a detection device for detecting a state of a waste toner container, which is a simple mechanism to detect both the presence and the loading level of the waste toner container. And the cost is few to detect multiple states of the container. Besides, an image forming apparatus using such a detection device is also provided. 
     A detection device for detecting a state of a waste toner container is provided in the present invention which comprises a first optical sensor and an actuation member. The first optical sensor comprises a first emitting unit and a first receiving unit. The first emitting unit is configured to emit a first optical signal, and the first receiving unit is configured to receive the first optical signal. A space for installation of the waste toner container is provided between the first emitting unit and the first receiving unit. The first optical signal travels along an optical path from the first emitting unit to the first receiving unit. The actuation member is movably disposed between the first emitting unit and the first receiving unit. The actuation member in a first position interrupts the optical path of the first optical signal; and the actuation member is moved by the waste toner container to a second position when at least a part of the waste toner container is placed in the space between the first emitting unit and the first receiving unit. The actuation member in the second position allows a passage of the first optical signal. 
     An image forming apparatus using such a detection device is also provided in the present invention and comprises a printing engine, a waste toner container and said device. 
     These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a diagram of an image forming apparatus according to an embodiment of the present invention. 
         FIG. 2  is a front view of the printing engine and detection device shown in  FIG. 1 , where the waste toner container is absent. 
         FIG. 3  is another front view of the printing engine and detection device shown in  FIG. 1 , where the waste toner container is present. 
         FIG. 4  is an enlarged partial view showing the waste toner container and the detection device shown in  FIG. 3 . 
         FIG. 5  is a right side view of the printing engine and detection device shown in  FIG. 2 . 
         FIG. 6  is a right side view of the printing engine and detection device shown in  FIG. 3 . 
         FIG. 7  is aperspective view of the waste toner container and detection device shown in  FIG. 6 , where the waste toner container is filled to the warning level. 
         FIG. 8  is aperspective view of the waste toner container and detection device shown in  FIG. 6 , where the waste toner container is full-loaded. 
         FIG. 9  is a diagram of another example of the actuation member, where the waste toner container is absent. 
         FIG. 10  is a diagram of the actuation member shown in  FIG. 9 , where the waste toner container is present. 
         FIG. 11  is a diagram of a detection device according to another embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the present invention will be described below with reference to the accompanying drawings. 
       FIG. 1  is a diagram of an image forming apparatus according to an embodiment of the present invention. Referring to  FIG. 1 , the image forming apparatus  1  comprises a printing engine  100 , a paper cassette  110 , a paper transferring system  130 , a fixing roller set  180 , a waste toner container  51 , a detection device  20 , and a processor  10 . The printing engine  100  comprises a photosensitive drum  140 , a developing unit  150 , a transfer roller  160 , and a cleaner  170 . The paper transferring system  130  transfers a paper S from the paper cassette  110  to the printing engine  100 . The toner in the developing unit  150  is attracted to the photosensitive drum  140 . When the paper S passes through the photosensitive drum  140 , the photosensitive drum  140  rotates and transfers the toner to the paper with the transfer roller  160 . The fixing roller set  180  fuses the toner and fixes it on the paper S by thermal and pressure. After the paper S goes through the printing engine  100  and the fixing roller set  180 , it is discharged from the image forming apparatus  1 . As the photosensitive drum  140  finishes transferring, the photosensitive drum  140  rotates to the cleaner  170  which removes the waste toner from the surface of the photosensitive drum  140 . The waste toner container  51  for gathering and storing the waste toner from the printing engine  100  is detachably disposed to one side of the printing engine  100 . The user will take out the waste toner container  51  and put in a new one if the old one is full. The detection device  20  is for detecting a state of the waste toner container  51 , for example, the presence or the loading level, or both. The processor  10  determines the state of the waste toner container  51  and then controls the image forming apparatus  1  according to the detecting results of the detection device  20 . 
       FIG. 2  is a front view of the printing engine and detection device shown in  FIG. 1 , where the waste toner container is absent.  FIG. 5  is a right side view of the printing engine and detection device shown in  FIG. 2 . Referring to  FIG. 2  and  FIG. 5 , the detection device  20  is disposed to one side of the printing engine  100 . A space for installation the waste toner container  51  is provided between the detection device  20  and the printing engine  100 . The detection device  20  comprises a first optical sensor  31 , a second optical sensor  41 , and an actuation member  21 . The first optical sensor  31  comprises a first emitting unit  311  configured to emit a first optical signal  313 , and a first receiving unit  312  configured to receive the first optical signal  313 . The second optical sensor  41  disposed below the first optical sensor  31  and comprises a second emitting unit  411  configured to emit a second optical signal  413 , and a second receiving unit  412  configured to receive the second optical signal  413 . The space is provided between the first emitting unit  311  and the first receiving unit  312 , and the first optical signal  313  travels along an optical path from the first emitting unit  311  to the first receiving unit  312 . A space is also provided between the second emitting unit  411  and the second receiving unit  412 , and the second optical signal  413  travels along another optical path from the second emitting unit  411  to the second receiving unit  412 . The first optical sensor  32  is used for detecting a loading level of the waste toner container  51 , and the second optical sensor  41  is used for detecting a warning level, which is under the loading level. Furthermore, the first optical sensor  31  and the second optical sensor  41  can detect the presence of the waste toner container  51  with the aid of the actuation member  21 . 
     The actuation member  21  is movably disposed between the first emitting unit  311  and the first receiving unit  312 . Referring to  FIG. 2 , the actuation member  21  in a first position interrupts the optical path of the first optical signal  313  while the waste toner container  51  is absent. The actuation member  21  is formed with an aperture  213  and pivotally mounted to a pivot  211  for pivotal movement. The aperture  213  makes the first optical signal  313  pass through the actuation member  21 . However, the aperture  213  isn&#39;t on the optical path of the first optical signal  313  when the actuation member  21  is in the first position. As a result, the first optical signal  313  doesn&#39;t pass through the actuation member  21 , and is interrupted by the opaque part of the actuation member  21 . The details will be given below. On the contrary, the second optical sensor  41  is disposed below the first optical sensor  31 , and the actuation member  21  isn&#39;t able to interrupt the second optical signal  413 . 
     Referring to  FIG. 5 , the actuation member  21  is disposed between the first emitting unit  311  and the first receiving unit  312 . The second emitting unit  411  and the second receiving unit  412  are disposed below the first emitting unit  311  and the first receiving unit  312 , but not limited to the right below direction. The first optical signal  313  is interrupted by the actuation member  21  when the waste toner container  51  is absent. However, the second optical signal  413  is received by the second receiving unit  412  without interrupting. As a result, the absence of the waste toner container  51  in an installed position is detected if the first receiving unit  312  receives no first optical signal  313  and the second receiving unit  412  receives the second optical signal  413 . The processor  10  determines that the waste toner container  51  is absent on the basis of the detecting result. The processor  10  is able to send a warning signal by displaying or light, to notify the user that the image forming apparatus  1  needs a waste toner container  51 . The processor  10  also can send a breaking signal to stop the operation for preventing waste toner spreading and staining the surrounding. 
       FIG. 3  is another front view of the printing engine and detection device shown in  FIG. 1 , where the waste toner container is present.  FIG. 4  is an enlarged partial view showing the waste toner container and the detection device shown in  FIG. 3 . Referring to  FIG. 3  and  FIG. 4 , the actuation member  21  is moved by the waste toner container  51  to a second position when the waste toner container  51  is in the installed position, or at least a part of the waste toner container  51  is placed in the space between the first emitting unit  311  and the first receiving unit  312 . The actuation member  21  is pushed along a moving direction A to the second position when it is installed. The actuation member  21  in the second position allows a passage of the first optical signal  313 . In addition, there are different members, apparatus, or methods which are also able to make the actuation member  21  move off the first position. For example, magnets may be attached to the waste toner container  51  and the actuation member  21  respectively. By the repulsion oflike poles, the actuation member  21  is pushed and moved off the first position while the waste toner container  51  is installed and approaches. Or, a solenoid valve which controls the actuation member  21  may be set in the first position or the second position. As the actuation member  21  is moved by the waste toner container  51  to the second position, the aperture  213  also moves into the optical path of the first optical signal  313 . The first optical signal  313  passes through the aperture  213  toward the waste toner container  51  which is installed. The aperture  213  can be replaced by other structures, like a gap, a piece of transparent material, or a designed shape which makes the first optical signal  313  pass through the actuation member  21 . 
     In the embodiment, the waste toner container  51  is able to transmit light. Therefore, when the vacant waste toner container  51  is installed, both the first optical signal  313  and the second optical signal  413  pass through the waste toner container  51  and arrive to the first receiving unit  312  and the second receiving unit  412  respectively.  FIG. 6  is a right side view of the printing engine and detection device shown in  FIG. 3 . Referring to  FIG. 6 , after the waste toner container  51  is installed, the first optical signal  313  passes through the aperture  213  and toward the waste toner container  51 . As a result, the presence of the waste toner container  51  in the installed position is detected if the first receiving unit  312  and the second receiving unit  412  receive the first optical signal  313  and the second optical signal  413  respectively. The processor  10  determines the waste toner container  51  is installed to the image forming apparatus  1  according to the detecting result. The waste toner container  51  would be composed of transparent material; or only part of regions of the waste toner container  51  is transparent. The transparent regions are faced to the first optical sensor  31  and the second optical sensor  41 , respectively. The transparent regions make the first optical signal  313  and the second optical signal  423  pass through the waste toner container  51 . 
     The first optical sensor  31  for detecting a loading level of the waste toner container  51  is disposed at an upper position. The second optical sensor  41  for detecting a warning level of the waste toner container  51  is disposed at a lower position. The warning level can be the level of 70% loading. It means that the waste toner container  51  is nearly full when the warning level is achieved, and it means full when the loading level is achieved.  FIG. 7  is a perspective view of the waste toner container and detection device shown in  FIG. 6 , where the waste toner container is filled to the warning level. The waste toner is piled up and makes the waste toner container  51  full after the image forming apparatus  1  operates. Referring to  FIG. 7 , the opaque waste toner piled up to/over the warning level makes the second optical signal  413  fail to pass through the waste toner container  51 . In this case, a nearly full state in the waste toner container  51  in the installed position is detected if the first receiving unit  312  receives the first optical signal  313  and the second receiving unit  412  receives no second optical signal  413 . The processor  10  determines that the waste toner container is nearly full according to the detecting result. Then the processor  10  controls the image forming apparatus  1  to send a signal to remind the user to prepare replacing the waste toner container  51 . 
       FIG. 8  is aperspective view of the waste toner container and detection device shown in  FIG. 6 , where the waste toner container is full-loaded. Referring to  FIG. 8 , the waste toner container  51  is full, as the waste toner is piled up to the loading level blocking both the first optical signal  313  and the second optical signal  413 . A full state in the waste toner container in the installed position is detected if neither of the first receiving unit  312  and the second receiving unit  412  receives the optical signal. The processor  10  determines that the waste toner is full, according to the detecting result. Similarly, the processor  10  controls the image forming apparatus  1  to send a signal to remind the user to replace the waste toner container  51 . The processor  10  is also able to order the image forming apparatus  1  to stop printing, for keeping the waste toner from spreading. The spreading waste toner is able to damage the image forming apparatus  1  and lower the quality of printing. It is not out of the invention to dispose the first optical sensor  31  and the second optical sensor  41  in other positions for detecting different levels. 
     As shown in  FIG. 4 , there is a collecting port  511  on the top of the waste toner container  51 . The waste toner scraped by the cleaner  170  (shown in  FIG. 1 ) is fed into the waste toner container  51  by passing through the collecting port  511 . As a result, the waste toner piles up within the waste toner container  51 . Besides, a third optical sensor is provided and disposed under the second optical sensor  41  if the image forming apparatus  1  is designed to detect another level, for example, the level of 60% loading. 
     The actuation member  21  can be replaced by another example of actuation member  71  in the embodiment.  FIG. 9  is a diagram of another example of the actuation member, where the waste toner container is absent. Referring to  FIG. 9 , the detection device further comprises an elastic connecting member  72  which connects the actuation member  71  to a frame  73  of the image forming apparatus  1 . By the elastic connecting member  72 , the actuation member  71  is flexibly disposed between the first emitting unit  311  and the first receiving unit  312 . The actuation member  71  is at a first position blocking the first optical signal  313  if the waste toner container  51  is absent.  FIG. 10  is a diagram of the actuation member shown in  FIG. 9 , where the waste toner container is present. Referring to  FIG. 10 , when the waste toner container  51  is installed, it pushes the actuation member  71  and compresses the elastic connecting member  72 . The actuation member  71  is pushed along a moving direction B to a second position. At the second position, the actuation member  71  is out of the optical path of the first optical signal  313  and allows the passage of the first optical signal  313 . When the waste toner container  51  is removed, the actuation member  71  comes back to the first position by the recovery of the elastic connecting member  72 , as shown in  FIG. 9 . The mechanism of detecting the loading level of the waste toner container  51  is the same as the detection device  20  having the actuation member  21 . So the detail of the detecting mechanism isn&#39;t given again. 
       FIG. 11  is a diagram of a detection device according to another embodiment of the present invention. Referring to  FIG. 11 , the detection device  20  comprises the actuation member  21  and the first optical sensor  31  without the second optical sensor  41 . The first optical sensor  31  comprises a first emitting unit  311  configured to emit a first optical signal  313 , and a first receiving unit  312  configured to receive the first optical signal  313 . The space is provided between the first emitting unit  311  and the first receiving unit  312 , and the first optical signal  313  travels along an optical path from the first emitting unit  311  to the first receiving unit  312 . The actuation members  21  in the embodiment and in the first embodiment are the same, and the actuation member  21  also can be replaced by the actuation member  71 . The detail about the actuation members  21  and  71  can be found in the first embodiment and will be omitted here. 
     The actuation member  21  is moved by the waste toner container  51  to a second position when the waste toner container  51  is in the installed position. The presence of the waste toner container  51  in the installed position is detected if the first receiving unit  312  receives the first optical signal  313 . And the absence of the waste toner container  51 , or a full state in the waste toner container  51 , is detected if the first receiving unit  312  receives no first optical signal  313 . In this embodiment, it is hard to detect the warning level (nearly full state) before full, and is hard to distinguish between the full state and the absence of the waste toner container  51 . However, it is still useful to warn users to check the state of the waste toner container  51 . When the first receiving unit  312  receives no first optical signal  313 , the processor  10  controls the image forming apparatus  1  to send a signal to remind the user to check the state of the waste toner container  51 , or orders the image forming apparatus  1  to stop printing. 
     Compared with the present invention, the conventional image forming apparatus detecting the loading level (full state) of the waste toner container is more complex and costs high price. If the conventional image forming apparatus is expected to detect the presence of the waste toner container, it needs to be equipped with other devices. On the contrary, the present invention costs lower price with simple structure. The present invention can detect both the presence and the loading of the waste toner container without other devices or assembling steps. It is able to remind the user that the waste toner container is nearly full by detecting a warning level. Compared with the other device which is only able to detect one state, the present invention can detect both two states and protect the image forming apparatus and the quality of printing more completely. 
     Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.