Patent ID: 12189326

DETAILED DESCRIPTION

A waste toner may be generated during an image forming process using an electrophotographic method. For example, after a toner image formed on a photosensitive drum is transferred to a printing medium, a toner may remain on the photosensitive drum. Before forming a next toner image, the toner remaining on the photosensitive drum may be removed. Hereinafter, the removed toner is referred to as a “waste toner.” The waste toner may be accommodated in a waste toner container. As a developing method, an automatic developer replenishment (ADR) method may be implemented. According to the ADR method, a developer, for example, a toner and a carrier, may be supplied to a developing device, and a surplus developer may be discharged from the developing device. Hereinafter, the discharged surplus developer is referred to as a “waste developer.” The waste developer may be accommodated in the waste toner container. The waste toner and the waste developer may be separately accommodated in the waste toner container. For example, the waste toner and the waste developer may be accommodated in a first reservoir and a second reservoir, respectively. A sensing structure to detect a full state of the first reservoir and the second reservoir may be implemented in the waste toner container.

The waste toner container according to the present example may include a housing having the first reservoir and the second reservoir, and a light guide member including a first detection portion and a second detection portion each including a pair of optical surfaces that are apart from each other, where the first and second detection portions are provided in the first reservoir and the second reservoir, respectively. The light guide member may connect a light emitting portion to a light receiving portion of a light sensor and may form a light path. For example, the waste toner removed from the photosensitive drum may be accommodated in the first reservoir, and the waste developer discharged from the developing device may be accommodated in the second reservoir. When the first reservoir is in a full state, the waste toner may accumulate around the photosensitive drum, and thus, a printed image may have background contamination. When the second reservoir is in a full state, the waste developer may not be able to be discharged from the developing device, and thus, developer pressure in the developing device may be increased so that a low image density of a printed image and toner leakage from the developing device, etc., may occur.

In the waste toner container according to the present example, a light path from the light emitting portion to the light receiving portion may be formed by the light guide member, and in the middle of the light path, the first detection portion and the second detection portion may be formed in the first reservoir and the second reservoir, respectively. When the waste toner or the waste developer accumulates around the first detection portion and/or the second detection portion, the amount of light passing through the first detection portion and/or the second detection portion may be reduced, or light may not pass through the first detection portion and/or the second detection portion. The light receiving portion may generate an electrical signal corresponding to the amount of light passing through the first and second detection portions. The electrical signal may be converted into a digital signal by, for example, an amplifier, a filter, and an analog-to-digital (AD) converter. A controller of an image forming apparatus may determine, based on the digital signal, whether any one of the first reservoir and the second reservoir is in a full state. According to this configuration, a single light sensor may be implemented and a full state of either of the first reservoir and the second reservoir may be detected.

For example, the light guide member may include: a facing portion having a first surface facing the light sensor and a second surface that is opposite to the first surface; a first light guide facing any one of the light emitting portion and the light receiving portion and extending from the second surface of the facing portion to the first reservoir; a second light guide to form, in the first reservoir, the first detection portion between the second light guide and the first light guide and extending from the first reservoir to the second reservoir; and a third light guide facing the other of the light emitting portion and the light receiving portion and extending from the second surface to the second reservoir to form the second detection portion between the third light guide and the second light guide. The first light guide and the third light guide may protrude from the first surface of the facing portion and may face the light sensor. The light guide member may include a first connection portion that provides a detour light path around the first detection portion to connect the first light guide with the second light guide, so that the facing portion, the first light guide, the second light guide, and the third light guide may be integrally formed with one another. The light guide member may include a second connection portion that provides a detour light path away from the second detection portion to connect the second light guide with the third light guide. A cross-sectional area of each of the first connection portion and the second connection portion may be less than a cross-sectional area of each of the first light guide, the second light guide, and the third light guide. The second reservoir may be located in the first reservoir. Hereinafter, examples of the waste toner container are described in detail by referring to the accompanying drawings. Also, in this specification and the drawings, components having substantially the same functional configurations are referred to by the same reference numerals, so as not to give repeated descriptions.

FIG.1is an exploded perspective view of an example of a waste toner container.FIG.2is an interior perspective view of the example of the waste toner container illustrated inFIG.1. InFIG.2, a second housing120and an inner cover130are omitted. Referring toFIGS.1and2, the example of the waste toner container may include: a housing100having a first reservoir101and a second reservoir102; a light sensor200including a light emitting portion210and a light receiving portion220; and a light guide member300to connect the light emitting portion210with the light receiving portion220, the light guide member300including a first detection portion301and a second detection portion302each including a pair of optical surfaces that are apart from each other, wherein the first and second detection portions301and302are provided in the first reservoir101and the second reservoir102, respectively.

The housing100may have an inner space, in which foreign substances are accommodated. For example, the housing100may include a first housing110and the second housing120covering the first housing110. The inner space of the housing100may include the first reservoir101and the second reservoir102. The first reservoir101and the second reservoir102may be divided from each other by a partition wall160and the inner cover130. In an example, the second reservoir102may be located in the first reservoir101. In an example, a waste toner removed from a photoconductor1001during an image forming process may be accommodated in the first reservoir101. A waste toner inlet portion140may be connected through the first reservoir101and may form an inlet passage of the waste toner. The waste toner removed from the photoconductor1001may be introduced into the first reservoir101through a waste toner discharge portion1002. When the waste toner container is mounted in a body of an image forming apparatus, the waste toner discharge portion1002may be inserted into the waste toner inlet portion140. A surplus developer, that is, a waste developer, discharged from a developing device1000using an ADR method, may be accommodated in the second reservoir102. A waste developer inlet portion150may be connected through the second reservoir102and may form an inlet passage of the waste developer. The waste developer discharged from the developing device1000may be introduced into the second reservoir102through a waste developer discharge portion1003. When the waste toner container is mounted in the body of the image forming apparatus, the waste developer discharge portion1003may be inserted into the waste developer inlet portion150. A distribution member170to distribute the waste toner in the first reservoir101may be provided in the first reservoir101. The distribution member170may include, for example, an auger extending in a longitudinal direction of the first reservoir101. When the waste toner container is mounted in the body of the image forming apparatus, the distribution member170may be driven by being connected to a driving motor provided in the body of the image forming apparatus. The distribution member170may transport the waste toner in an axial direction to distribute the waste toner in the first reservoir101. Although not shown in the drawings, the second reservoir102may also include a distribution member.

The light sensor200may include the light emitting portion210and the light receiving portion220. The light receiving portion220may generate an electrical signal corresponding to the amount of light that is received. A signal processor may be provided in the body of the image forming apparatus. The signal processor may include, for example, an amplifier, a filter, and an AD converter. The electrical signal may be converted into a digital signal by the signal processor. A controller that is not shown may detect a full state of the first reservoir101and/or the second reservoir102, based on the digital signal.

The light guide member300may form a light path connecting the light emitting portion210with the light receiving portion220. The light guide member300may include the first detection portion301and the second detection portion302. The first detection portion301may be located in the first reservoir101, and the second detection portion302may be located in the second reservoir102. The first detection portion301may be located in a position of the first reservoir101to detect a full state of the first reservoir101. For example, the first detection portion301may be located in the vicinity of an upper wall101aof the first reservoir101. The first detection portion301may include a pair of optical surfaces that are apart from each other. Light may be emitted from any one of the pair of optical surfaces and may pass into the first reservoir101to be incident on the other optical surface. When there is a waste toner between the pair of optical surfaces of the first detection portion301, the amount of light that is incident on the other optical surface may be reduced, or light may not be incident on the other optical surface. Likewise, the second detection portion302may be located in a position of the second reservoir102to detect a full state of the second reservoir102. For example, the second detection portion302may be located in the vicinity of an upper wall102aof the second reservoir102. The second detection portion302may include a pair of optical surfaces that are apart from each other. Light may be emitted from any one of the pair of optical surfaces and may pass into the second reservoir102to be incident on the other optical surface. When there is a waste developer between the pair of optical surfaces, the amount of light that is incident on the other optical surface may be reduced or light may not be incident on the other optical surface.

FIG.3is a perspective view of an example of the light guide member300. Referring toFIG.3, the light guide member300may include a facing portion340, a first light guide310, a second light guide320, and a third light guide330. The facing portion340, the first light guide310, the second light guide320, and the third light guide330may include a transmissive material to allow transmission of light. Light may be totally reflected at boundary surfaces between the facing portion340, the first light guide310, the second light guide320, and the third light guide330, and an external portion thereof, and thus, the light may be propagated in the facing portion340, the first light guide310, the second light guide320, and the third light guide330.

The facing portion340may face the light sensor200. The facing portion340may include a first surface341facing the light sensor200and a second surface342that is opposite to the first surface341. The first light guide310may face any one of the light emitting portion210and the light receiving portion220and may extend from the second surface342of the facing portion340to the first reservoir101. In the present example, the first light guide310may face the light emitting portion210. The first light guide310may include a first optical surface391and a second optical surface392. The first optical surface391may face the light emitting portion210.

The second light guide320may form the first detection portion301between the second light guide320and the first light guide310in the first reservoir101. The second light guide320may extend from the first reservoir101to the second reservoir102. For example, the second light guide320may include a third optical surface393facing the second optical surface392of the first light guide310and a fourth optical surface394located in the second reservoir102. The third optical surface393may face the second optical surface392in the first reservoir101. The third optical surface393may be apart from the second optical surface392. The first detection portion301may be formed by the second optical surface392and the third optical surface393facing each other.

The third light guide330may face the other of the light emitting portion201and the light receiving portion220, for example, the light receiving portion220, and may extend from the second surface342of the facing portion340to the second reservoir102. The third light guide330may form the second detection portion302between the third light guide330and the second light guide320in the second reservoir102. For example, the third light guide330may include a fifth optical surface395facing the fourth optical surface394of the second light guide320and a sixth optical surface396connected to the second surface342of the facing portion340and facing the light receiving portion220.

The first light guide310and the third light guide330may be connected to each other via the facing portion340. Based on this configuration, the facing portion340, the first light guide310, and the third light guide330may be integrally formed with one another. The facing portion340may have a plate shape having a thickness which is relatively much less than a thickness of the first through third light guides310through330. Based on this configuration, the amount of light that is incident onto the first light guide310through the first optical surface391and that passes through the facing portion340to be emitted from the sixth optical surface396of the third light guide330may be minimized.

As illustrated inFIG.3with broken lines, the first optical surface391may protrude from the first surface341of the facing portion340. As illustrated inFIG.3with broken lines, the sixth optical surface396may protrude from the first surface341of the facing portion340. Light irradiated from the light emitting portion210and into the light guide member300through the first optical surface391may be propagated inside the light guide member300so as to be emitted through the sixth optical surface396to be incident onto the light receiving portion220. In other words, the light emitted from the light emitting portion210may be incident onto the light receiving portion220through the first optical surface391, the first light guide310, the second optical surface392, the first reservoir101, the third optical surface393, the second light guide320, the fourth optical surface394, the second reservoir102, the fifth optical surface395, the third light guide330, and the sixth optical surface396. In this process, the second optical surface392and the third optical surface393may form the first detection portion301to detect whether or not the first reservoir101is full of the waste toner, and the fourth optical surface394and the fifth optical surface395may form the second detection portion302to detect whether or not the second reservoir102is full of the waste developer.

FIG.4is a view showing an operation of the example of the waste toner container illustrated inFIGS.1through3, the operation indicating a state in which the first reservoir101and the second reservoir102are not full.FIG.5is a view showing an operation of the example of the waste toner container illustrated inFIGS.1through3, the operation indicating a state in which the first reservoir101is full of a waste toner, and the second reservoir102is not full of a waste developer.FIG.6is a view showing an operation of the example of the waste toner container illustrated inFIGS.1through3, the operation indicating a state in which the first reservoir101is not full of a waste toner, and the second reservoir102is full of a waste developer. Referring toFIGS.4through6, the operation of the example of the waste toner container is described.

First, referring toFIG.4, a waste toner WT and a waste developer WD may be accommodated in the first reservoir101and the second reservoir102, respectively. A level of the waste toner WT in the first reservoir101may be lower than the first detection portion301. A level of the waste developer WD in the second reservoir102may be lower than the second detection portion302. Because a light path between the second optical surface392and the third optical surface393is open (not obstructed by the waste toner WT), light emitted from the second optical surface392may be incident onto the third optical surface393. Also, because a light path between the fourth optical surface394and the fifth optical surface395is open (not obstructed by the waste developer WD), light emitted from the fourth optical surface394may be incident onto the fifth optical surface395. Thus, light emitted from the light emitting portion210may be propagated in the first light guide310, the second light guide320, and the third light guide330and may be incident onto the light receiving portion220through the sixth optical surface396. The light receiving portion220may generate an electrical signal proportional to the amount of the incident light, and a signal processor may convert the electrical signal into a digital value corresponding to the amount of light. A controller of an image forming apparatus that is not shown may, for example, compare a reference light amount value stored in a memory with the digital value. For example, the digital value may be greater than the reference light amount value. In this case, the controller may determine that the first reservoir101and the second reservoir102are not in a full state.

Next, referring toFIG.5, a level of the waste toner WT in the first reservoir101may be higher than the first detection portion301. A level of the waste developer WD in the second reservoir102may be lower than the second detection portion302. Because a light path between the second optical surface392and the third optical surface393is blocked by the waste toner WT, light emitted from the second optical surface392may not be incident onto the third optical surface393, or the amount of light that is incident may be very small. Because a light path between the fourth optical surface394and the fifth optical surface395is open, light emitted from the fourth optical surface394may be incident onto the fifth optical surface395. Thus, light emitted from the light emitting portion210may be blocked between the first light guide310and the second light guide320and may not be incident onto the light receiving portion220, or merely a very small amount of light may be incident onto the light receiving portion220. The light receiving portion220may generate an electrical signal proportional to the amount of incident light, and a signal processor may convert the electrical signal into a digital value. A controller of an image forming apparatus that is not shown may, for example, compare a reference light amount value stored in a memory with the digital value. For example, the digital value may be less than the reference light amount value. The controller may determine that the first reservoir101or the second reservoir102is in a full state.

Next, referring toFIG.6, a level of the waste toner WT in the first reservoir101may be lower than the first detection portion301. A level of the waste developer WD in the second reservoir102may be higher than the second detection portion302. Because a light path between the second optical surface392and the third optical surface393is open, light emitted from the second optical surface392may be incident onto the third optical surface393. Because a light path between the fourth optical surface394and the fifth optical surface395is blocked by the waste developer WD, light emitted from the fourth optical surface394may not be incident onto the fifth optical surface395, or the amount of incident light may be very small. Thus, light emitted from the light emitting portion210may be blocked between the second light guide320and the third light guide330and may not be incident onto the light receiving portion220, or merely a very small amount of light may be incident onto the light receiving portion220. The light receiving portion220may generate an electrical signal proportional to the amount of incident light, and a signal processor may convert the electrical signal into a digital value. A controller of an image forming apparatus that is not shown may, for example, compare a reference light amount value stored in a memory with the digital value, and may determine that the first reservoir101or the second reservoir102is in a full state.

When the first reservoir101is at a full state but the full state is not detected, the waste toner removed from the photoconductor1001may not be introduced to the first reservoir101. Then, pressure of the waste toner in a waste toner reservoir space of the developing device1000may be increased, and thus, the waste toner may be leaked to the outside of the developing device1000. The waste toner on a surface of the photoconductor1001may not be properly removed, and thus, a printed image may be contaminated by the waste toner and the image quality of the printed image may deteriorate. When the second reservoir102is at a full state but the full state is not detected, pressure of the developer in the developing device1000may be excessively increased. Then, the charging amount of a toner may become insufficient to degrade the image quality, and the toner may be scattered to the outside of the developing device1000in a developing process from the developing device1000to the photoconductor1001. Also, the developer may be fixed in the developing device1000to damage the developing device1000. As described above, according to the waste toner container according to the present examples, the light guide member300having the two detection portions, that is, the first and second detection portions301and302, may be implemented, and thus, a single light sensor, that is, the light sensor200, may be used to detect a full state of the first reservoir101and the second reservoir102. When at least one of the first reservoir101and the second reservoir102is in a full state, the light sensor200may detect the full state. Thus, the waste toner container may be replaced by a new container at an appropriate time point, and thus, deterioration of the image quality or the breakdown of the developing device1000may be prevented. Also, whether or not the first reservoir101and the second reservoir102are in a full state may be detected by the single light sensor200, and thus, the cost of a waste toner container, which is a consumable product, may be reduced, and the burden of a user regarding the consumable product may be alleviated. Also, a first connection portion351may function as an enforcement member to stably maintain a distance and a relative location between the second optical surface392and the third optical surface393. Based on this configuration, in a manufacturing process of the light guide member300and in a process of assembling the light guide member300onto the housing100, errors with respect to the distance and the relative location between the second optical surface392and the third optical surface393may be reduced, and thus, whether or not the first reservoir101is in a full state may be reliably detected.

Referring toFIG.3again, the light guide member300may include the first connection portion351provides a detour light path around the first detection portion301to connect the first light guide310with the second light guide320. The first connection portion351may extend from the first light guide310, may provide a detour light path around the second optical surface392and the third optical surface393, and may be connected to the second light guide320. Based on this configuration, the first light guide310and the second light guide320may be integrally formed with each other. Also, the light guide member300may be realized, the light guide member300including the first light guide310, the second light guide320, and the third light guide330that are integrally formed with one another via the facing portion340and the first connection portion351.

In order to minimize the amount of light propagated from the first light guide310to the second light guide320through the first connection portion351, a cross-sectional area of the first connection portion351may be less than a cross-sectional area of each of the first light guide310and the second light guide320. For example, the cross-sectional area of the first connection portion351may be equal to or less than a half of each of the cross-sectional area of the first light guide310and the second light guide320. Here, the cross-sectional areas of the first light guide310and the second light guide320may be cross-sectional areas of the second optical surface392and the third optical surface393, respectively.

Referring toFIG.3, the light guide member300may include a second connection portion352provides a detour light path away from the second detection portion302to connect the second light guide320with the third light guide330. The second connection portion352may extend from the second light guide320, may provide a detour light path away from the fourth optical surface394and the fifth optical surface395, and may be connected to the third light guide330. Based on this configuration, the second light guide320and the third light guide330may be integrally formed with each other. Also, the light guide member300may be realized, the light guide member300including the first light guide310, the second light guide320, and the third light guide330that are integrally formed with one another via the facing portion340, the first connection portion351, and the second connection portion352. Also, the second connection portion352may function as an enforcement member to stably maintain a distance and a relative location between the fourth optical surface394and the fifth optical surface395. Based on this configuration, in a manufacturing process of the light guide member300and in a process of assembling the light guide member300onto the housing100, errors with respect to the distance and the relative location between the fourth optical surface394and the fifth optical surface395may be reduced, and thus, whether or not the second reservoir102is in a full state may be reliably detected.

In order to minimize the amount of light propagated from the second light guide320to the third light guide330through the second connection portion352, a cross-sectional area of the second connection portion352may be less than a cross-sectional area of each of the second light guide320and the third light guide330. For example, the cross-sectional area of the second connection portion352may be equal to or less than a half of each of the cross-sectional area of the second light guide320and the third light guide330. Here, the cross-sectional areas of the second light guide320and the third light guide330may be cross-sectional areas of the fourth optical surface394and the fifth optical surface395, respectively.

In other examples, a structure of a light guide member may be modified.FIGS.7through10are perspective views of various examples of light guide members. Referring toFIG.7, a light guide member300-1according to the present example may be different from the light guide member300illustrated inFIGS.1through3, in that in the light guide member300-1, the first light guide310, the second light guide320, and the third light guide330are formed as separate members. The first light guide310, the second light guide320, and the third light guide330may be coupled to the housing100such that the first light guide310, the second light guide320, and the third light guide330may form the first detection portion301and the second detection portion302in the first reservoir101and the second reservoir102, respectively. Referring toFIG.8, a light guide member300-2according to the present example may be different from the light guide member300illustrated inFIGS.1through3, in that in the light guide member300-2, the first light guide310and the third light guide330are integrally formed with each other via the facing portion340. A first light guide member381in which the facing portion340, the first light guide310, and the third light guide330are integrally formed with one another may be coupled to the housing100, and the second light guide320may be coupled to the housing100to form the first detection portion301and the second detection portion302in the first reservoir101and the second reservoir102, respectively. Referring toFIG.9, a light guide member300-3according to the present example may be different from the light guide member300illustrated inFIGS.1through3, in that in the light guide member300-3, the first light guide310and the second light guide320are integrally formed with each other via the first connection portion351. A second light guide member382in which the first light guide310and the second light guide320are integrally formed with each other may be coupled to the housing100, and the third light guide330may be coupled to the housing100to form the second detection portion302in the second reservoir102. Referring toFIG.10, a light guide member300-4according to the present example may be different from the light guide member300illustrated inFIGS.1through3in that in the light guide member300-4, the first light guide310, the second light guide320, and the third light guide330are integrally formed with one another through the first connection portion351and the second connection portion352.

FIG.11is a rear perspective view of an example of a waste toner container. Referring toFIG.11, a waste toner container according to the present example may be different from the examples of the waste toner container illustrated inFIGS.1through10in that in the waste toner container according to the present example, the light sensor200is omitted. Hereinafter, different aspects are mainly described. Referring toFIG.11, a through-hole113may be provided in a rear surface112of the housing100. The first optical surface391and the sixth optical surface396are exposed through the through-hole113. When the waste toner container is mounted in a body of an image forming apparatus, the first optical surface391may face the light emitting portion210of the light sensor200provided in the body, and the sixth optical surface396may face the light receiving portion220of the light sensor200provided in the body. Based on this configuration, the cost of the waste toner container may be reduced.

FIG.12is a schematic cross-sectional view of an example of a waste toner container. Referring toFIG.12, a waste toner container according to the present example may be applied to a color image forming apparatus. The color image forming apparatus may include four photoconductors and four developing devices to form toner images having, for example, a cyan color, a magenta color, a yellow color, and a block color. The color image forming apparatus may include four waste toner discharge portions and four waste developer discharge portions. Thus, the waste toner container may include four waste toner inlet portions140corresponding to the four waste toner discharge portions and four waste developer inlet portions150corresponding to the four waste developer discharge portions. The four waste toner inlet portions140may be connected to the first reservoir101and the four waste developer inlet portions150may be connected to the second reservoir102. A structure to detect a full state of the first reservoir101and the second reservoir102may be the same as described with reference toFIGS.1through11.

It should be understood that examples described herein should be considered in a descriptive sense only and not for purposes of limitation. Descriptions of features or aspects within each example should typically be considered as available for other similar features or aspects in other examples. While one or more examples have been described with reference to the figures, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope as defined by the following claims.