Patent Description:
In electrophotographic image forming devices, one or more replaceable toner containers may be used to supply toner for printing onto sheets of media. Each toner container often includes a toner agitator assembly that agitates and mixes toner stored in a toner reservoir to prevent the toner from clumping and that moves the toner to an outlet of the toner container. It is often desired for each toner container to communicate characteristics of the toner container to the image forming device for proper operation. For example, it may be desired to communicate such information as authentication or validation information, toner fill amount (see <CIT> and <CIT>), toner color, toner type, etc..

A toner container for use in an electrophotographic image forming device according to one example embodiment includes a housing having a reservoir for storing toner. An input gear is positioned on the housing for mating with a corresponding output gear in the image forming device when the toner container is installed in the image forming device. A toner agitator is movably positioned in the reservoir. The toner agitator is operatively connected to the input gear such that rotation of the input gear in a first rotational direction causes movement of the toner agitator for agitating toner in the reservoir. An encoded member is encoded with authentication information of the toner container and is operatively connected to the input gear such that rotation of the input gear in a second rotational direction causes movement of the encoded member for communicating the authentication information of the toner container to a controller of the image forming device when the toner container is installed in the image forming device.

In some embodiments, the toner container includes a one-way clutch positioned to decouple the toner agitator from the input gear when the input gear rotates in the second rotational direction such that the toner agitator does not move with the input gear when the input gear rotates in the second rotational direction.

In some embodiments, the toner agitator includes a shaft rotatably positioned in the reservoir and a plurality of extensions outward from the shaft for agitating toner in the reservoir. In some embodiments, the toner agitator includes a rotatable auger positioned to move toner to an outlet port on the housing for exiting toner from the toner container.

Embodiments include those wherein the encoded member is rotatably connected to the input gear such that rotation of the input gear in the second rotational direction causes rotation of the encoded member. In some embodiments, the encoded member is positioned on an axial face of the input gear. In some embodiments, the encoded member is coaxial with the input gear.

In some embodiments the auger and the toner agitator may each be operatively connected to a drive gear that is directly connected to the input gear and the one-way clutch is positioned to decouple the drive gear from the input gear when the input gear rotates in the second rotational direction such that the drive gear does not rotate with the input gear when the input gear rotates in the second rotational direction.

In some embodiments, the encoded member is directly connected to the input gear. In other embodiments, the encoded member is indirectly connected to the input gear.

Embodiments include those wherein the encoded member is encoded with authentication information of the toner container by a random distribution of magnetized particles dispersed on the encoded member.

A toner container for use in an electrophotographic image forming device according to another example embodiment includes a housing having a reservoir for storing toner. An input gear is positioned on the housing for mating with a corresponding output gear in the image forming device when the toner container is installed in the image forming device. A toner agitator is movably positioned in the reservoir. The toner agitator is operatively connected to the input gear such that rotation of the input gear in a first rotational direction causes movement of the toner agitator for agitating toner in the reservoir. An encoded member is encoded with identifying information of the toner container and is operatively connected to the input gear such that rotation of the input gear in a second rotational direction causes movement of the encoded member for communicating the identifying information of the toner container to a sensor of the image forming device when the toner container is installed in the image forming device. A one-way clutch is positioned to decouple the toner agitator from the input gear when the input gear rotates in the second rotational direction such that the toner agitator does not move with the input gear when the input gear rotates in the second rotational direction.

The toner agitator may include a shaft rotatably positioned in the reservoir and a plurality of extensions outward from the shaft for agitating toner in the reservoir.

Further the toner agitator may include a rotatable auger positioned to move toner to an outlet port on the housing for exiting toner from the toner container.

The encoded member may be rotatably connected to the input gear such that rotation of the input gear in the second rotational direction causes rotation of the encoded member. In this case the encoded member may be positioned on an axial face of the input gear or the encoded member may be coaxial with the input gear.

In some embodiments the encoded member may be directly connected to the input gear.

Further the encoded member may be encoded with identifying information of the toner container by a random distribution of magnetized particles dispersed on the encoded member.

A toner container for use in an electrophotographic image forming device according to another example embodiment includes a housing having a reservoir for storing toner. An input gear is positioned on the housing for mating with a corresponding output gear in the image forming device when the toner container is installed in the image forming device. A toner agitator is rotatably positioned in the reservoir. The toner agitator is operatively connected to the input gear such that rotation of the input gear in a first rotational direction causes rotation of the toner agitator in an operative rotational direction of the toner agitator for agitating toner in the reservoir. An encoded member is encoded with information pertaining to the toner container and is operatively connected to the input gear such that rotation of the input gear in a second rotational direction causes movement of the encoded member for reading of the information pertaining to the toner container by a sensor when the toner container is installed in the image forming device. A one-way clutch is configured to limit rotation of the toner agitator with the input gear to the operative rotational direction of the toner agitator.

A toner container for use in an electrophotographic image forming device according to another example embodiment includes a housing having a reservoir for storing toner. An input gear is positioned on the housing for mating with a corresponding output gear in the image forming device when the toner container is installed in the image forming device. An outlet port is positioned on the housing and is in fluid communication with the reservoir for exiting toner from the toner container. An auger is positioned within the housing and is operatively connected to the input gear such that rotation of the input gear in a first rotational direction causes rotation of the auger in an operative rotational direction of the auger. The auger is positioned to move toner to the outlet port when the auger rotates in the operative rotational direction of the auger. A toner agitator is positioned in the reservoir that includes a rotatable drive shaft. The toner agitator is operatively connected to the input gear such that rotation of the input gear in the first rotational direction causes rotation of the drive shaft in an operative rotational direction of the toner agitator for agitating toner in the reservoir. An encoded member is encoded with identifying information of the toner container and is operatively connected to the input gear such that rotation of the input gear in a second rotational direction causes movement of the encoded member for communicating the identifying information of the toner container to a sensor of the image forming device when the toner container is installed in the image forming device. A one-way clutch is positioned to decouple the auger and the toner agitator from the input gear when the input gear rotates in the second rotational direction such that the auger and the drive shaft do not rotate with the input gear when the input gear rotates in the second rotational direction.

The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of the present disclosure, and together with the description serve to explain the principles of the present disclosure.

In the following description, reference is made to the accompanying drawings where like numerals represent like elements. The embodiments are described in sufficient detail to enable those skilled in the art to practice the present disclosure. It is to be understood that other embodiments may be utilized and that process, electrical, and mechanical changes, etc., may be made without departing from the scope of the present disclosure. Examples merely typify possible variations. Portions and features of some embodiments may be included in or substituted for those of others. The following description, therefore, is not to be taken in a limiting sense and the scope of the present disclosure is defined only by the appended claims and their equivalents.

Referring now to the drawings and particularly to <FIG>, there is shown a block diagram depiction of an imaging system <NUM> according to one example embodiment. Imaging system <NUM> includes an image forming device <NUM> and a computer <NUM>. Image forming device <NUM> communicates with computer <NUM> via a communications link <NUM>. As used herein, the term "communications link" generally refers to any structure that facilitates electronic communication between multiple components and may operate using wired or wireless technology and may include communications over the Internet.

In the example embodiment shown in <FIG>, image forming device <NUM> is a multifunction machine (sometimes referred to as an all-in-one (AIO) device) that includes a controller <NUM>, a print engine <NUM>, a laser scan unit (LSU) <NUM>, an imaging unit <NUM>, a toner cartridge <NUM>, a user interface <NUM>, a media feed system <NUM>, a media input tray <NUM>, a scanner system <NUM>, a drive motor <NUM> and a sensor <NUM>. Image forming device <NUM> may communicate with computer <NUM> via a standard communication protocol, such as, for example, universal serial bus (USB), Ethernet or IEEE <NUM>. Image forming device <NUM> may be, for example, an electrophotographic printer/copier including an integrated scanner system <NUM> or a standalone electrophotographic printer.

Controller <NUM> includes a processor unit and associated electronic memory <NUM>. The processor may include one or more integrated circuits in the form of a microprocessor or central processing unit and may be formed as one or more application-specific integrated circuits (ASICs). Memory <NUM> may be any volatile or non-volatile memory or combination thereof, such as, for example, random access memory (RAM), read only memory (ROM), flash memory and/or non-volatile RAM (NVRAM). Memory <NUM> may be in the form of a separate memory (e.g., RAM, ROM, and/or NVRAM), a hard drive, a CD or DVD drive, or any memory device convenient for use with controller <NUM>. Controller <NUM> may be, for example, a combined printer and scanner controller.

In the example embodiment illustrated, controller <NUM> communicates with print engine <NUM> via a communications link <NUM>. Controller <NUM> communicates with imaging unit <NUM> and processing circuitry <NUM> thereon via a communications link <NUM>. Controller <NUM> communicates with toner cartridge <NUM> and processing circuitry <NUM> thereon via a communications link <NUM>. Controller <NUM> communicates with media feed system <NUM> via a communications link <NUM>. Controller <NUM> communicates with scanner system <NUM> via a communications link <NUM>. User interface <NUM> is communicatively coupled to controller <NUM> via a communications link <NUM>. Controller <NUM> communicates with drive motor <NUM> via a communications link <NUM>. Controller <NUM> communicates with sensor <NUM> via a communications link <NUM>. Controller <NUM> processes print and scan data and operates print engine <NUM> during printing and scanner system <NUM> during scanning. Processing circuitry <NUM>, <NUM> may provide authentication functions, safety and operational interlocks, operating parameters and usage information related to imaging unit <NUM> and toner cartridge <NUM>, respectively. Each of processing circuitry <NUM>, <NUM> includes a processor unit and associated electronic memory. As discussed above, the processor may include one or more integrated circuits in the form of a microprocessor or central processing unit and may include one or more application-specific integrated circuits (ASICs). The memory may be any volatile or non-volatile memory or combination thereof or any memory device convenient for use with processing circuitry <NUM>, <NUM>.

Computer <NUM>, which is optional, may be, for example, a personal computer, including electronic memory <NUM>, such as RAM, ROM, and/or NVRAM, an input device <NUM>, such as a keyboard and/or a mouse, and a display monitor <NUM>. Computer <NUM> also includes a processor, input/output (I/O) interfaces, and may include at least one mass data storage device, such as a hard drive, a CD-ROM and/or a DVD unit (not shown). Computer <NUM> may also be a device capable of communicating with image forming device <NUM> other than a personal computer such as, for example, a tablet computer, a smartphone, or other electronic device.

In the example embodiment illustrated, computer <NUM> includes in its memory a software program including program instructions that function as an imaging driver <NUM>, e.g., printer/scanner driver software, for image forming device <NUM>. Imaging driver <NUM> is in communication with controller <NUM> of image forming device <NUM> via communications link <NUM>. Imaging driver <NUM> facilitates communication between image forming device <NUM> and computer <NUM>. One aspect of imaging driver <NUM> may be, for example, to provide formatted print data to image forming device <NUM>, and more particularly to print engine <NUM>, to print an image. Another aspect of imaging driver <NUM> may be, for example, to facilitate collection of scanned data from scanner system <NUM>.

In some circumstances, it may be desirable to operate image forming device <NUM> in a standalone mode. In the standalone mode, image forming device <NUM> is capable of functioning without computer <NUM>. Accordingly, all or a portion of imaging driver <NUM>, or a similar driver, may be located in controller <NUM> of image forming device <NUM> so as to accommodate printing and/or scanning functionality when operating in the standalone mode.

Print engine <NUM> includes a laser scan unit (LSU) <NUM>, toner cartridge <NUM>, imaging unit <NUM> and a fuser <NUM>, all mounted within image forming device <NUM>. Imaging unit <NUM> is removably mounted in image forming device <NUM> and includes a developer unit <NUM> that houses a toner sump and a toner development system. In one embodiment, the toner development system utilizes what is commonly referred to as a single component development system. In this embodiment, the toner development system includes a toner adder roll that provides toner from the toner sump to a developer roll. A doctor blade provides a metered uniform layer of toner on the surface of the developer roll. In another embodiment, the toner development system utilizes what is commonly referred to as a dual component development system. In this embodiment, toner in the toner sump of developer unit <NUM> is mixed with magnetic carrier beads. The magnetic carrier beads may be coated with a polymeric film to provide triboelectric properties to attract toner to the carrier beads as the toner and the magnetic carrier beads are mixed in the toner sump. In this embodiment, developer unit <NUM> includes a magnetic roll that attracts the magnetic carrier beads having toner thereon to the magnetic roll through the use of magnetic fields. Imaging unit <NUM> also includes a cleaner unit <NUM> that houses a photoconductive drum and a waste toner removal system.

Toner cartridge <NUM> is removably mounted in imaging forming device <NUM> in a mating relationship with developer unit <NUM> of imaging unit <NUM>. An outlet port on toner cartridge <NUM> communicates with an inlet port on developer unit <NUM> allowing toner to be periodically transferred from toner cartridge <NUM> to resupply the toner sump in developer unit <NUM>.

The electrophotographic printing process is well known in the art and, therefore, is described briefly herein. During a printing operation, laser scan unit <NUM> creates a latent image on the photoconductive drum in cleaner unit <NUM>. Toner is transferred from the toner sump in developer unit <NUM> to the latent image on the photoconductive drum by the developer roll (in the case of a single component development system) or by the magnetic roll (in the case of a dual component development system) to create a toned image. The toned image is then transferred to a media sheet received by imaging unit <NUM> from media input tray <NUM> for printing. Toner may be transferred directly to the media sheet by the photoconductive drum or by an intermediate transfer member that receives the toner from the photoconductive drum. Toner remnants are removed from the photoconductive drum by the waste toner removal system. The toner image is bonded to the media sheet in fuser <NUM> and then sent to an output location or to one or more finishing options such as a duplexer, a stapler or a hole-punch.

Referring now to <FIG>, toner cartridge <NUM> and imaging unit <NUM> are shown according to one example embodiment. Imaging unit <NUM> includes a developer unit <NUM> and a cleaner unit <NUM> mounted on a common frame <NUM>. Developer unit <NUM> includes a toner inlet port <NUM> positioned to receive toner from toner cartridge <NUM>. As discussed above, imaging unit <NUM> and toner cartridge <NUM> are each removably installed in image forming device <NUM>. Imaging unit <NUM> is first slidably inserted into image forming device <NUM>. Toner cartridge <NUM> is then inserted into image forming device <NUM> and onto frame <NUM> in a mating relationship with developer unit <NUM> of imaging unit <NUM> as indicated by the arrow A shown in <FIG>, which also indicates the direction of insertion of imaging unit <NUM> and toner cartridge <NUM> into image forming device <NUM>. This arrangement allows toner cartridge <NUM> to be removed and reinserted easily when replacing an empty toner cartridge <NUM> without having to remove imaging unit <NUM>. Imaging unit <NUM> may also be readily removed as desired in order to maintain, repair or replace the components associated with developer unit <NUM>, cleaner unit <NUM> or frame <NUM> or to clear a media jam.

With reference to <FIG>, toner cartridge <NUM> includes a housing <NUM> having an enclosed reservoir <NUM> (<FIG>) for storing toner. Housing <NUM> includes a top <NUM>, a bottom <NUM>, first and second sides <NUM>, <NUM>, a front <NUM> and a rear <NUM>. Front <NUM> of housing <NUM> leads during insertion of toner cartridge <NUM> into image forming device <NUM> and rear <NUM> trails. In one embodiment, each side <NUM>, <NUM> of housing <NUM> includes an end cap <NUM>, <NUM> mounted, e.g., by fasteners or a snap-fit engagement, to side walls <NUM>, <NUM> of a main body <NUM> of housing <NUM>. An outlet port <NUM> in fluid communication with reservoir <NUM> is positioned on front <NUM> of housing <NUM> near side <NUM> for exiting toner from toner cartridge <NUM>. Housing <NUM> may include legs <NUM> on bottom <NUM> to assist with the insertion of toner cartridge <NUM> into image forming device <NUM> and to support housing <NUM> when toner cartridge <NUM> is set on a flat surface. A handle <NUM> may be provided on top <NUM> or rear <NUM> of housing <NUM> to assist with insertion and removal of toner cartridge <NUM> into and out of image forming device <NUM>.

Sides <NUM>, <NUM> may each include an alignment guide <NUM> that extends outward from the respective side <NUM>, <NUM> to assist the insertion of toner cartridge <NUM> into image forming device <NUM>. Alignment guides <NUM> travel in corresponding guide slots in image forming device <NUM> that guide the insertion of toner cartridge <NUM> into image forming device <NUM>. In the example embodiment illustrated, an alignment guide <NUM> is positioned on the outer side of each end cap <NUM>, <NUM>. Alignment guides <NUM> may run along a front-to-rear dimension of housing <NUM> as shown in <FIG>.

With reference to <FIG>, in the example embodiment illustrated, a toner agitator assembly <NUM> is rotatably positioned within toner reservoir <NUM>. Toner agitator assembly <NUM> includes an auger <NUM> having first and second ends 132a, 132b and a spiral screw flight. Auger <NUM> is positioned in a channel <NUM> that runs along the front <NUM> of housing <NUM> from side <NUM> to side <NUM>. Channel <NUM> is oriented generally horizontal when toner cartridge <NUM> is installed in image forming device <NUM>. Auger <NUM> includes a rotational axis <NUM>. In operation, auger <NUM> rotates in an operative rotational direction <NUM>. Rotation of auger <NUM> delivers toner in channel <NUM> to outlet port <NUM>, which is positioned at the bottom of channel <NUM> so that gravity assists in exiting toner through outlet port <NUM>. Channel <NUM> includes an open portion 128a and may include an enclosed portion 128b. Open portion 128a is open to toner reservoir <NUM> and extends from side <NUM> toward second end 132b of auger <NUM>. Enclosed portion 128b of channel <NUM> extends from side <NUM> and encloses second end 132b of auger <NUM>. In this embodiment, outlet port <NUM> is positioned at the bottom of enclosed portion 128b of channel <NUM>.

Toner agitator assembly <NUM> also includes a rotatable drive shaft <NUM> and one or more toner agitators <NUM> in the form of extensions outward from drive shaft <NUM>. Drive shaft <NUM> includes a rotational axis <NUM>. In the example embodiment illustrated, rotational axis <NUM> of drive shaft <NUM> is parallel to rotational axis <NUM> of auger <NUM>. In operation, drive shaft <NUM> rotates in an operative rotational direction <NUM>. Toner agitators <NUM> rotate with drive shaft <NUM> around rotational axis <NUM> when drive shaft <NUM> rotates in operative rotational direction <NUM>. As drive shaft <NUM> rotates, toner agitators <NUM> agitate and mix the toner stored in toner reservoir <NUM> and, in the embodiment illustrated, move toner toward channel <NUM> where auger <NUM> moves the toner to outlet port <NUM>. In the example embodiment illustrated, first and second ends of drive shaft <NUM> extend through aligned openings in side walls <NUM>, <NUM>, respectively. However, drive shaft <NUM> may take other positions and orientations as desired. Bushings may be provided on an inner side of each side wall <NUM>, <NUM> where drive shaft <NUM> passes through side walls <NUM>, <NUM>.

A drive train <NUM> on housing <NUM> is operatively connected to auger <NUM> and drive shaft <NUM> and may be positioned within a space formed between end cap <NUM> and side wall <NUM>. Drive train <NUM> includes an input gear <NUM> that engages with a corresponding output gear in image forming device <NUM> that provides rotational motion from drive motor <NUM> in image forming device <NUM> to input gear <NUM>. As shown in <FIG>, in one embodiment, a front portion of input gear <NUM> is exposed at the front <NUM> of housing <NUM> near the top <NUM> of housing <NUM> where input gear <NUM> engages the output gear in image forming device <NUM>. With reference back to <FIG>, in the embodiment illustrated, drive train <NUM> also includes a drive gear <NUM> on one end of drive shaft <NUM> that is connected to input gear <NUM> either directly or via one or more intermediate gears to rotate drive shaft <NUM>. In the embodiment illustrated, drive train <NUM> also includes a drive gear <NUM> on first end 132a of auger <NUM> that is connected to input gear <NUM> either directly or via one or more intermediate gears to rotate auger <NUM>.

With reference to <FIG> and <FIG>, toner cartridge <NUM> includes an encoded member <NUM> that is movably connected to drive train <NUM>, either directly or indirectly to input gear <NUM>. In the example embodiment illustrated, encoded member <NUM> includes a rotatable disk <NUM> operatively connected to drive train <NUM>, such as, for example, positioned on an outboard face <NUM> of input gear <NUM>, coaxially with input gear <NUM> as illustrated. Disk <NUM> may be formed integrally with input gear <NUM> or separately attached to input gear <NUM>. In other embodiments, encoded member <NUM> is, for example, translatable, such as by way of a rack and pinion arrangement or a cam and follower arrangement. Information pertaining to toner cartridge <NUM> is encoded on encoded member <NUM>. Encoded member <NUM> is detectable by sensor <NUM> in image forming device <NUM> when toner cartridge <NUM> is installed in image forming device <NUM> permitting sensor <NUM> to communicate the encoded information of toner cartridge <NUM> to controller <NUM> of image forming device <NUM> via communications link <NUM>. The encoded information may include, for example, authentication information such as a signature, serial number, or other identifier for authenticating or validating toner cartridge <NUM> upon installation of toner cartridge <NUM> in image forming device <NUM>. The encoded information may include, for example, characteristics of toner cartridge <NUM> such as toner color, initial toner fill amount, toner type, geographic region, manufacture location, manufacture date, etc..

In the example embodiment illustrated, authentication information is encoded on encoded member <NUM> by randomly distributed magnetized particles <NUM> dispersed on disk <NUM>, e.g., on the surface of disk <NUM> and/or within disk <NUM>. Particles <NUM> are distributed randomly such that it is difficult to reproduce the exact distribution and alignment of particles <NUM> thereby making the distribution difficult to copy. In this embodiment, sensor <NUM> is positioned in close proximity to encoded member <NUM> when toner cartridge <NUM> is installed in image forming device <NUM>, such as, adjacent to and facing the outboard side of disk <NUM> as schematically illustrated in <FIG>. At predetermined times, such as upon the installation of a new toner cartridge in image forming device <NUM>, sensor <NUM> measures the magnetic field of disk <NUM> in one, two or three dimensions as disk <NUM> rotates due to rotation of input gear <NUM> by motor <NUM>. The magnetic field values measured by sensor <NUM> are communicated to controller <NUM> via communications link <NUM>. Controller <NUM> may then compare the magnetic field values received from sensor <NUM> to values stored during manufacture in non-volatile memory of processing circuitry <NUM> of toner cartridge <NUM>. Controller <NUM> may confirm the authenticity of toner cartridge <NUM> to controller <NUM> if the magnetic field values received from sensor <NUM> match the values stored in non-volatile memory of processing circuitry <NUM>.

While the example embodiment illustrated includes information encoded by a random distribution of magnetized particles and detection by measuring the magnetic field of the particles, it will be appreciated that information may be encoded by a random distribution of non-magnetized particles and detection may occur according to other means, such as, for example, by measuring an optical property of the particles. Further, in lieu of a random pattern, information may be encoded according to a predetermined pattern using any suitable indicia and detection method. However, as discussed above, it is preferred for authentication information to be encoded according to a random pattern so that the encoded information is more difficult for a counterfeiter to reproduce.

With reference back to <FIG> and <FIG>, in the example embodiment illustrated, at least a portion of encoded member <NUM> is exposed on the exterior of toner cartridge <NUM> above a rotational axis <NUM> of input gear <NUM> for reading by sensor <NUM>. For example, in the embodiment illustrated, encoded member <NUM> is exposed through a cutout <NUM> in end cap <NUM> that is positioned above rotational axis <NUM> of input gear <NUM>.

<FIG> shows drive train <NUM> in greater detail according to one example embodiment. In the example embodiment illustrated, input gear <NUM> is a compound gear that includes a first portion 142a that mates with the corresponding output gear in image forming device <NUM> when toner cartridge <NUM> is installed in image forming device <NUM> and a second portion 142b that meshes with drive gear <NUM> in order to provide rotational motion to drive shaft <NUM>. First portion 142a of input gear <NUM> also meshes with an idler gear <NUM> that, in turn, meshes with a compound idler gear <NUM>. Compound idler gear <NUM> includes a first portion 150a that meshes with idler gear <NUM> and a second portion 150b that meshes with drive gear <NUM> in order to provide rotational motion to auger <NUM>. It will be appreciated that the embodiment illustrated in <FIG> is merely an example and that drive train <NUM> may take many suitable configurations for transferring rotational motion from input gear <NUM> to toner agitator assembly <NUM> and to encoded member <NUM>.

In operation, controller <NUM> drives motor <NUM> in a first rotational direction to drive toner agitator assembly <NUM> and in a second rotational direction to perform a reading of encoded member <NUM> by sensor <NUM>. In particular, when controller <NUM> drives motor <NUM> in the first rotational direction, input gear <NUM> rotates in a first rotational direction 152a and, in turn, rotates auger <NUM> and drive shaft <NUM> in operative rotational directions <NUM>, <NUM> to feed toner from toner cartridge <NUM> to developer unit <NUM>. When controller <NUM> drives motor <NUM> in the second rotational direction, input gear <NUM> rotates in a second rotational direction 152b. Sensor <NUM> is configured to read encoded member <NUM> as input gear <NUM> rotates in rotational direction 152b. In this manner, sensor <NUM> is able to perform a reading of encoded member <NUM> separately from a toner feed operation so that the authenticity or validity of toner cartridge <NUM> may be checked prior to the first use of toner cartridge <NUM> or at other times when toner cartridge <NUM> is not in use.

With reference to <FIG>, toner agitator assembly <NUM> includes a one-way clutch <NUM> that limits the rotational motion of at least one component of toner agitator assembly <NUM> to its operative rotational direction. For example, the one-way clutch may limit auger <NUM> and/or drive shaft <NUM> to its operative rotational direction <NUM>, <NUM>. In the example embodiment illustrated, one-way clutch <NUM> is operatively connected to drive gear <NUM> such that when input gear <NUM> rotates in rotational direction 152a, drive shaft <NUM> rotates in operative rotational direction <NUM> and when input gear <NUM> rotates in rotational direction 152b, drive shaft <NUM> is decoupled and does not rotate with input gear <NUM>. In this manner, drive shaft <NUM> and toner agitators <NUM> do not rotate while sensor <NUM> performs a reading of encoded member <NUM>. As a result, torque on drive shaft <NUM> and toner agitators <NUM> from toner stored in reservoir <NUM> does not affect the movement of encoded member <NUM> thereby permitting better control of encoded member <NUM> while sensor <NUM> performs a reading of encoded member <NUM> and improving the accuracy of the reading performed by sensor <NUM>. Further, in some embodiments, toner agitators <NUM> may include flexible wipers that could displace or become damaged upon rotating counter to operative rotational direction <NUM>. Decoupling drive shaft <NUM> from input gear <NUM> when input gear <NUM> rotates in rotational direction 152b prevents this from occurring.

In the example embodiment illustrated, one-way clutch <NUM> includes a clutch disk <NUM> positioned against an outboard face <NUM> of drive gear <NUM>. Clutch disk <NUM> is biased against outboard face <NUM> of drive gear <NUM> by a bias spring <NUM>. A bracket <NUM> positioned between end cap <NUM> and side wall <NUM> locates spring <NUM> relative to clutch disk <NUM> and drive gear <NUM>. In the example embodiment illustrated, bracket <NUM> also locates input gear <NUM> relative to end cap <NUM> and to the rest of drive train <NUM>.

With reference to <FIG>, in the example embodiment illustrated, drive shaft <NUM> includes a male spline <NUM> positioned near an axial end of drive shaft <NUM>. Male spline <NUM> passes through aligned central openings <NUM>, <NUM> in drive gear <NUM> and clutch disk <NUM>, respectively. A diameter of central opening <NUM> of drive gear <NUM> is larger than male spline <NUM> of drive shaft <NUM> permitting drive gear <NUM> to rotate independent of drive shaft <NUM>. Central opening <NUM> of clutch disk <NUM> includes a female spline <NUM> that matably receives male spline <NUM> of drive shaft <NUM> such that drive shaft <NUM> is rotatably coupled to clutch disk <NUM>.

With reference to <FIG>, clutch disk <NUM> includes one or more engagement members <NUM> that protrude axially from an inboard face <NUM> of clutch disk <NUM> toward outboard face <NUM> of drive gear <NUM>. Each engagement member <NUM> includes a contact face <NUM> positioned to transfer rotational motion from clutch disk <NUM> to drive gear <NUM>. In the embodiment illustrated, contact faces <NUM> are positioned perpendicular to inboard face <NUM> of clutch disk <NUM>; however, contact faces <NUM> may take other suitable orientations as desired. Each engagement member <NUM> also includes a ramp <NUM> on inboard face <NUM> of clutch disk <NUM> that tapers axially inward (toward inboard face <NUM> of clutch disk <NUM>) away from a corresponding contact face <NUM> of the engagement member <NUM> along a circumferential dimension of clutch disk <NUM>.

Engagement members <NUM> of clutch disk <NUM> are positioned to engage corresponding dwells or openings <NUM> on drive gear <NUM> shown in <FIG> to transfer rotational motion from drive gear <NUM> to clutch disk <NUM> when input gear <NUM> rotates in rotational direction 152a. Specifically, with reference to <FIG> and <FIG>, when input gear <NUM> rotates in rotational direction 152a, drive gear <NUM> rotates in a first rotational direction 194a as a result of the gear mesh between input gear <NUM> and drive gear <NUM>. As drive gear <NUM> rotates in rotational direction 194a, drive gear <NUM> rotates independent of clutch disk <NUM> with engagement members <NUM> of clutch disk <NUM> sliding across outboard face <NUM> of drive gear <NUM> until engagement members <NUM> of clutch disk <NUM> reach openings <NUM> of drive gear <NUM>. When engagement members <NUM> of clutch disk <NUM> reach openings <NUM> of drive gear <NUM>, clutch disk <NUM> translates axially toward drive gear <NUM> and engagement members <NUM> extend into openings <NUM> as a result of the bias applied to clutch disk <NUM> by spring <NUM>. As drive gear <NUM> continues to rotate in rotational direction 194a, the surfaces of drive gear <NUM> that form openings <NUM> come into contact with contact faces <NUM> of engagement members <NUM> as shown in <FIG>. The contact between contact faces <NUM> of engagement members <NUM> of clutch disk <NUM> and the surfaces forming openings <NUM> of drive gear <NUM> transfer rotational motion from drive gear <NUM> to clutch disk <NUM> causing clutch disk <NUM> to rotate with drive gear <NUM> as drive gear <NUM> continues to rotate in rotational direction 194a. The engagement between male spline <NUM> of drive shaft <NUM> and female spline <NUM> of clutch disk <NUM>, in turn, causes drive shaft <NUM> and toner agitators <NUM> to rotate with clutch disk <NUM>. In this manner, when drive motor <NUM> rotates in its first rotational direction and input gear <NUM> rotates in rotational direction 152a, drive shaft <NUM> and toner agitators <NUM> rotate in operative rotational direction <NUM> in order to mix the toner in reservoir <NUM> and to move toner toward auger <NUM>.

With reference to <FIG> and <FIG>, when input gear <NUM> rotates in the opposite rotational direction 152b, drive gear <NUM> rotates in a second rotational direction 194b as a result of the gear mesh between input gear <NUM> and drive gear <NUM>. As drive gear <NUM> rotates in rotational direction 194b, drive gear <NUM> continuously rotates independent of clutch disk <NUM> such that drive shaft <NUM> and toner agitators <NUM> do not rotate with drive gear <NUM>. Specifically, as drive gear <NUM> rotates in rotational direction 194b, engagement members <NUM> of clutch disk <NUM> slide across outboard face <NUM> of drive gear <NUM> until engagement members <NUM> of clutch disk <NUM> reach openings <NUM> of drive gear <NUM>. When engagement members <NUM> of clutch disk <NUM> reach openings <NUM> of drive gear <NUM>, clutch disk <NUM> translates axially toward drive gear <NUM> and engagement members <NUM> extend into openings <NUM> as a result of the bias applied to clutch disk <NUM> by spring <NUM> as discussed above. However, as drive gear <NUM> continues to rotate in rotational direction 194b, contact between the surfaces of drive gear <NUM> that form openings <NUM> and ramps <NUM> of engagement members <NUM> cause clutch disk <NUM> to translate axially away from drive gear <NUM> against the bias applied to clutch disk <NUM> by spring <NUM> thereby causing engagement members <NUM> of clutch disk <NUM> to resume sliding across outboard face <NUM> of drive gear <NUM> as shown in <FIG>. In this manner, when drive motor <NUM> rotates in its second rotational direction and input gear <NUM> rotates in rotational direction 152b, encoded member <NUM> rotates with input gear <NUM> for sensing by sensor <NUM>, but drive shaft <NUM> and toner agitators <NUM> do not rotate with input gear <NUM> so that torque on drive shaft <NUM> and toner agitators <NUM> from toner stored in reservoir <NUM> does not interfere with the movement of encoded member <NUM>.

While the example embodiment illustrated in <FIG> includes a one-way clutch <NUM> that includes a clutch disk <NUM> and bias spring <NUM>, one or more one-way clutches of any suitable construction may be used to limit the rotational motion of at least one component of toner agitator assembly <NUM> to its operative rotational direction. For example, the one-way clutch may include one or more of a one-way bearing sprag clutch, a trapped roller clutch, a backstop cam clutch, a pawl and ratchet clutch, and a wrap spring clutch.

As discussed above, drive train <NUM> may take many suitable configurations for transferring rotational motion from input gear <NUM> to toner agitator assembly <NUM> and to encoded member <NUM>. Further, while the exampled embodiment illustrated includes a one-way clutch <NUM> positioned on drive gear <NUM> connected to drive shaft <NUM>, one or more one-way clutches may be positioned at any suitable point(s) along drive train <NUM> to limit the rotational motion of at least one component of toner agitator assembly <NUM> to its operative rotational direction. For example, a first one-way clutch may be positioned to limit the motion of auger <NUM> to operative rotational direction <NUM> and a second one-way clutch may be positioned to limit the motion of drive shaft <NUM> and toner agitators <NUM> to operative rotational direction <NUM>. Alternatively, a single one-way clutch may be positioned to limit the motion of auger <NUM> as well as drive shaft <NUM> and toner agitators <NUM> to their operative rotational directions <NUM>, <NUM>.

For example, <FIG> and <FIG> illustrate a drive train <NUM> that includes an input gear <NUM> that engages with a corresponding output gear in image forming device <NUM>. Drive train <NUM> also includes a drive gear <NUM> connected to an end of drive shaft <NUM> and a drive gear <NUM> connected to an end of auger <NUM>. Encoded member <NUM> is positioned on input gear <NUM> as discussed above. In this embodiment, a one-way clutch <NUM> is operatively connected to input gear <NUM> in order to limit rotation of drive gears <NUM> and <NUM> to a single direction to limit rotation of auger <NUM> and drive shaft <NUM> to their operative rotational directions <NUM>, <NUM>. In this embodiment, one-way clutch <NUM> includes a drive gear <NUM> biased against an inboard face <NUM> of input gear <NUM> by a bias spring <NUM>. A bracket <NUM> positioned between end cap <NUM> and side wall <NUM> locates spring <NUM> relative to drive gear <NUM>. In this embodiment, drive gear <NUM> includes a series of circumferentially spaced, radially extending lugs <NUM>. In this embodiment, input gear <NUM> includes one or more engagement members <NUM> that protrude axially from inboard face <NUM> of input gear <NUM> toward an outboard face <NUM> of drive gear <NUM>. Each engagement member <NUM> includes a contact face <NUM> positioned to transfer rotational motion from input gear <NUM> to drive gear <NUM>. Each engagement member <NUM> also includes a ramp <NUM> on inboard face <NUM> of input gear <NUM> that tapers axially inward (toward inboard face <NUM> of input gear <NUM>) away from a corresponding contact face <NUM> of the engagement member <NUM> along a circumferential dimension of input gear <NUM>.

When input gear <NUM> rotates in a rotational direction 1152a, contact between contact faces <NUM> of engagement members <NUM> of input gear <NUM> and lugs <NUM> of drive gear <NUM> causes drive gear <NUM> to rotate with input gear <NUM> as discussed above with respect to engagement members <NUM> of clutch disk <NUM> and openings <NUM> of drive gear <NUM>. Drive gear <NUM> connected to drive shaft <NUM> is meshed with drive gear <NUM> such that rotation of drive gear <NUM> causes drive gear <NUM>, drive shaft <NUM> and toner agitators <NUM> to rotate with input gear <NUM> when input gear <NUM> rotates in rotational direction 1152a. Drive gear <NUM> is connected to drive gear <NUM> by way of an idler gear <NUM> and a compound idler gear <NUM> such that rotation of drive gear <NUM> causes drive gear <NUM> and auger <NUM> to rotate with input gear <NUM> when input gear <NUM> rotates in rotational direction 1152a.

When input gear <NUM> rotates in an opposite rotational direction 1152b, contact between lugs <NUM> of drive gear <NUM> and ramps <NUM> of engagement members <NUM> of input gear <NUM> cause drive gear <NUM> to translate axially away from input gear <NUM> against the bias applied to drive gear <NUM> by spring <NUM> as discussed above with respect to engagement members <NUM> of clutch disk <NUM> and openings <NUM> of drive gear <NUM>. As a result, drive gear <NUM> continuously rotates independent of drive gear <NUM> such that auger <NUM>, drive shaft <NUM> and toner agitators <NUM> do not rotate with input gear <NUM> when input gear <NUM> rotates in rotational direction 1152b.

While the example embodiments illustrated include a one-way clutch to limit the rotational motion of at least one component of toner agitator assembly <NUM> to its operative rotational direction, toner cartridge <NUM> may also include a one-way clutch positioned to limit rotation of encoded member <NUM> to a single direction as desired for reading by sensor <NUM>. For example, <FIG> illustrates encoded member <NUM> positioned on an outboard face <NUM> of a drive gear <NUM> that is coupled to input gear <NUM> by an idler gear <NUM> and a drive gear <NUM>. Drive gear <NUM>, idler gear <NUM> and drive gear <NUM> constitute part of a drive train <NUM>. Drive train <NUM> also includes input gear <NUM> coupled to drive gears <NUM>, <NUM> by way of idler gears <NUM>, <NUM> and one-way clutch <NUM> as discussed above with respect to <FIG>. Drive train <NUM> also includes a one-way clutch <NUM> coupled to idler gear <NUM> in order to limit rotation of drive gear <NUM> to a single direction in the same manner as drive gear <NUM> discussed above with respect to <FIG> and <FIG>. In this manner, rotation of drive gear <NUM> and encoded member <NUM> are limited to an operative rotational direction <NUM> for reading by sensor <NUM>. Specifically, in this embodiment, when drive motor <NUM> rotates in its first rotational direction and input gear <NUM> rotates in rotational direction 152a, drive shaft <NUM> and toner agitators <NUM> rotate in operative rotational direction <NUM> but encoded member <NUM> does not rotate with input gear <NUM>. When drive motor <NUM> rotates in its second rotational direction and input gear <NUM> rotates in rotational direction 152b, encoded member <NUM> rotates in operative rotational direction <NUM> but drive shaft <NUM> and toner agitators <NUM> do not rotate with input gear <NUM>.

As discussed above, while the example embodiments illustrated include an encoded member <NUM> that includes information encoded by a random distribution of magnetized particles, information may be encoded on an encoded member that is movably connected to an input gear of toner cartridge <NUM> according to many other suitable methods. For example, <FIG> illustrates an encoded member <NUM> in the form of rotatable disk <NUM> that is connected to input gear <NUM> by a drive gear <NUM>. Disk <NUM> includes a series of cutouts <NUM> therethrough that are spaced along a circumferential dimension of disk <NUM> according to a predetermined pattern to encode information pertaining to toner cartridge <NUM>. In this embodiment, sensor <NUM> includes an optical emitter and an optical detector positioned to detect the pattern of cutouts <NUM> through disk <NUM> as disk <NUM> rotates.

While the example embodiments discussed above include a toner agitator assembly <NUM> that includes a rotatable auger <NUM> and a rotatable drive shaft <NUM> having toner agitators <NUM> extending outward therefrom, it will be appreciated that toner agitator assembly <NUM> may include any suitable combination of rotating, shifting, reciprocating or otherwise movable toner agitators, which may take many shapes, forms, sizes and orientations. For example, the toner agitator(s) may include any suitable combination of one or more paddles, augers, rakes, combs, scoops, plows, arms, extensions, prongs, flaps, mixers, conveyors, screws, etc..

While the example embodiment shown in <FIG> includes a pair of replaceable units in the form of toner cartridge <NUM> and imaging unit <NUM>, it will be appreciated that the replaceable unit(s) of image forming device <NUM> may employ any suitable configuration as desired. For example, in one embodiment, the main toner supply for image forming device <NUM>, developer unit <NUM> and cleaner unit <NUM> are housed in one replaceable unit. In another embodiment, the main toner supply for image forming device <NUM> and developer unit <NUM> are provided in a first replaceable unit and cleaner unit <NUM> is provided in a second replaceable unit. Further, while the example image forming device <NUM> discussed above includes one toner cartridge <NUM> and corresponding imaging unit <NUM>, in the case of an image forming device configured to print in color, separate replaceable units may be used for each toner color needed. For example, in one embodiment, the image forming device includes four toner cartridges and four corresponding imaging units, each toner cartridge containing a particular toner color (e.g., black, cyan, yellow or magenta) and each imaging unit corresponding with one of the toner cartridges to permit color printing. Further, while the example embodiments illustrated pertain to a toner agitator assembly <NUM> and an encoded member <NUM> of a toner cartridge <NUM>, it will be appreciated that they may apply to a toner agitator assembly and an encoded member of any toner container including, for example, a developer unit, an imaging unit or a waste toner container.

Claim 1:
A toner container (<NUM>) for use in an electrophotographic image forming device, comprising:
a housing (<NUM>) having a reservoir (<NUM>) for storing toner;
an input gear (<NUM>) positioned on the housing <NUM>) for mating with a corresponding output gear in the image forming device when the toner container is installed in the image forming device;
a toner agitator (<NUM>) movably positioned in the reservoir (<NUM>), the toner agitator (<NUM>) is operatively connected to the input gear (<NUM>) such that rotation of the input gear (<NUM>) in a first rotational direction causes movement of the toner agitator (<NUM>) for agitating toner in the reservoir (<NUM>); and
an encoded member (<NUM>) encoded with authentication information of the toner container (<NUM>) and operatively connected to the input gear (<NUM>) such that rotation of the input gear (<NUM>) in a second rotational direction causes movement of the encoded member (<NUM>) for communicating the authentication information of the toner container (<NUM>) to a controller of the image forming device when the toner container (<NUM>) is installed in the image forming device.