Abstract:
A printer cartridge fastener comprising a curved portion adapted to grasp a printer cartridge overhang; a main body connected to the curved portion, the main body comprising a first side connected to the curved section; and a second side positioned opposite the first side; and an elongate portion connected to the second side of the main body, the elongate portion configured to abut to a printer cartridge portion positioned substantially perpendicular to the overhang.

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
     None 
     FIELD OF INVENTION 
     The present invention relates to electrophotography, particularly methods and apparatus for manufacturing or remanufacturing toner cartridges. 
     BACKGROUND 
     Used printer cartridges are often remanufactured. The process of remanufacturing a printer cartridge may include cleaning the cartridge, repairing damaged parts, replacing worn parts, or replenishing the cartridge with toner. The toner in the cartridge is typically stored in the cartridge&#39;s toner hopper, which has a toner hopper opening. During remanufacturing, it is desirable to have full access to the toner hopper opening in order to remove any remaining traces of old seals, dump the old toner, completely clean the interior of the toner hopper, replenish it with new toner, and seal the toner hopper opening with a new seal. 
     Some toner hopper openings of some cartridges, such as cartridges for use with Hewlett Packard Company&#39;s HP4200 printers, are blocked by their respective developer or mag roller housing. The developer roller housing is typically ultrasonically welded around the toner hopper opening. To gain access to the toner hopper opening during the remanufacturing process, the developer roller housing is usually detached from the toner hopper by breaking the ultrasonic welds thereby splitting the cartridge into two sections-namely, the toner hopper section and the developer roller housing section. The splitting process may involve using conventional tools, such as blades, screw drivers, and rotary tools, in combination with force to cut or break the ultrasonic or plastic welds. 
     After all the worn or damaged parts have been replaced or repaired and the toner has been replenished, the cartridge is usually re-assembled. Re-attaching the developer roller housing and the toner hopper by ultrasonic welding may not be cost effective to many remanufacturers. Cost effective methods and devices for re-attaching the developer roller housing with the toner hopper during remanufacturing are desired and are addressed by the present invention. 
     BRIEF DESCRIPTION 
     The invention includes a printer cartridge fastener comprising a curved portion adapted to grasp a printer cartridge overhang; a main body connected to the curved portion, the main body comprising a first side connected to the curved section; and a second side positioned opposite the first side; and an elongate portion connected to the second side of the main body, the elongate portion configured to abut to a printer cartridge portion positioned substantially perpendicular to the overhang. 
     The above description sets forth, rather broadly, a summary of embodiments of the present invention so that the detailed description that follows may be better understood and contributions of the present invention to the art may be better appreciated. Some of the embodiments of the present invention may not include all of the features or characteristics listed in the above summary. There may be, of course, other features of the invention that will be described below and may form the subject matter of claims. In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and to the arrangement of the components set forth in the following description or as illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is substantially a plan view of an existing printer cartridge for which the device and printer remanufacturing method of the present invention may be applied. 
         FIG. 2  is substantially a perspective view of a fastening device of the present invention. 
         FIG. 3  is substantially a perspective view of the fastening device shown in  FIG. 2  being used in the remanufacturing of the printer cartridge of  FIG. 1 . 
         FIG. 4  is substantially a side view of the fastening device of  FIG. 2  being positioned on a printer cartridge. 
         FIG. 5  is substantially a side view of the fastening device of  FIG. 2  being positioned on a printer cartridge. 
         FIG. 6  is substantially a side view of another fastening device embodiment of the present invention. 
         FIG. 7  is substantially a front view of the elongate portion of the fastening device embodiment of  FIG. 6 . 
         FIG. 8  is substantially a front view of the elongate portion of yet another embodiment of the fastening device of the present invention. 
         FIG. 9  is substantially a front view of the printer cartridge of  FIG. 1  with the waste hopper removed and with the multiple fastening devices being used to attach the developer roller housing with the toner hopper. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part of this application. The drawings show, by way of illustration, specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. 
     Referring to  FIG. 1 , printer cartridge  20 , such as the cartridge for Hewlett Packard&#39;s HP4200 printer, may have a toner hopper  22  where toner (not shown) is stored. The toner hopper  22  may have a toner hopper opening (not shown) that allows the toner to be discharged to the other parts of the cartridge and eventually to the paper. The cartridge  20  may also have a developer roller housing  24 , which is attached to the toner hopper  22  and which contains the developer roller (not shown). The developer roller is typically a cylindrical roller that acquires toner on its surface and uniformly charges the toner deposited on its surface. The developer roller transfers the toner to an organic photoconductor drum (not shown), which carries the image to be printed to a piece of paper. The developer roller may sometimes be referred to as a “mag roller” in the industry. 
     The printer cartridge  20  may also have a waste hopper  26  attached to the developer roller housing  24 . The waste hopper  26  stores the excess toner removed from the drum after the image has been printed on a paper. Excess toner is typically removed from the drum and discarded in the waste hopper  26  to provide a clean print without unwanted print. Old toner may be removed off the toner hopper  22  by blowing air through the toner hopper opening. Traces of old seal or seal adhesive may be removed from the surfaces surrounding the toner hopper opening. New toner may be added through the toner hopper opening, and a new seal may be installed to cover the toner hopper opening. After the desired cartridge remanufacturing steps have been performed, the developer roller housing  24  may be attached to the toner hopper  22  using the methods and device of the present invention. 
     Referring to  FIG. 2 , the present invention includes a fastener  26 , which preferably includes a main body  28 . The main body  28  may be substantially flexible, substantially flat, and substantially rectangular in shape. Of course, the shape of the main body  28  may vary. The main body  28  preferably includes a middle portion  31  two opposing sides  30  and  32 . First side  30  is preferably connected to a curved portion  34 , which may be C-shaped and may resemble a hook. The curved portion  34  preferably extends towards the underside  36  of the fastener  26 . 
     The fastener  26  preferably also includes an elongate portion  38 , which preferably extends from the second side  32  of the main body  28 . In the preferred embodiment, the elongate portion  38  preferably defines a curved surface  40  and recess  42  substantially in between a proximal end  44  and a distal end  46  of the elongate portion  38 . The curved surface  40  preferably curves towards the middle portion  31  and is preferably configured to abut to a portion of the toner hopper. The recess  42  may be shaped as round, oblong, or any other shapes that would accommodate a toner hopper protrusion, as further described. The recess  42  may be eliminated for instance if the remanufacturing method of choice is to cut the toner hopper protrusion. In other embodiments (not shown), the elongate portion  38  may be a straight or bent piece of material. In the preferred embodiment, the main body  28 , the elongate portion  38 , and the curved portion  34  are of equal width. Of course, the widths of the main body  28 , the elongate portion  38 , and the curved portion  34  can vary. The fastener  26  may be made of commonly known materials, such as metal, and may be made of commonly known methods, such as stamping and bending. 
     In use, a developer roller housing  24  is preferably positioned next to a toner hopper  22  ( FIG. 3 ). Fastener  26  is preferably used to join the developer roller housing  24  with the toner hopper  22  by inserting the curved portion  34  of the fastener through a developer roller housing slot  48 . The main body  28  of the fastener  26  is preferably positioned such that it spans across a portion of the developer roller housing  24  and a portion of the toner hopper  22 . The elongate portion  38  of the fastener  26  is preferably positioned proximate to the toner hopper  22 . It can be realized that the curved portion  34  and the elongate portion  38  of the fastener exert opposing pressures that aid in joining the developer roller housing  24  with the toner hopper  22 . 
     Referring now to  FIG. 4 , developer roller housing  24  may define at least two overhangs  50  and  52  that protrude from a developer roller housing wall  54 . The overhangs  50  and  52  define a developer roller housing slot  56  where curved portion  34  of the fastener  26  may be inserted. Curved portion end  58  of the fastener  26  may abut the underside  60  of overhang  50 . Opposite the curved portion end  58 , the elongate portion  38  of the fastener  26  is preferably stretched to allow its distal end  46  to be positioned above a portion of the toner hopper  22 . 
     Referring now to  FIG. 5 , the main body  28  of the fastener  26  is preferably pushed down until the main body  28  is proximately positioned to the top surfaces of the developer roller housing  24  and the toner hopper  22 . The main body  28  preferably lies on the top surfaces of the developer roller housing  24  and the toner hopper  22  in a slanted manner. Curved surface  40  of the elongate portion  38  preferably contacts in part the wall  62  of the toner hopper  22 . It can be realized that as curved surface  40  presses on wall  62 , curved portion  34  may press on overhang  52  thereby joining the developer roller housing  24  and the toner hopper  22  together. If the toner wall  62  includes a protrusion  64 , the protrusion may be accommodated by recess  42  ( FIG. 3 ) defined by the curved surface  40  of the fastener  26 . It can be appreciated that by surrounding the protrusion  64  with the elongate portion  38  of the fastener  26 , the fastener  26  may be secured from movements, such as sliding or lateral movements, that may loosen the attachment of the developer roller housing  24  to the toner hopper  22 . 
     Referring now to  FIGS. 6-8 , various embodiments of the fastener  26  are shown. In  FIG. 6 , fastener  26  preferably includes a plurality of barbs  70  attached at the distal end  46  of the elongate portion  38 . Barbs  70  are preferably attached in an inclined position to the distal end of the elongate portion  38  that faces towards the curved portion  34 . When used, barbs  70  are preferably configured to penetrate through a cartridge portion, such as a toner hopper wall, to prevent detachment of the elongate portion  38  of the fastener  26  from the cartridge. In  FIG. 7 , another fastener embodiment may include barbs  70   a  and  70   b  attached side by side to the distal end  46  of the elongate portion  38  of the fastener. The elongate portion  38  of the fastener embodiment preferably defines a U-shaped slot  72  in lieu of the recess  42 . The U-shaped slot  72  is preferably configured to accommodate a cartridge protrusion, such as protrusion  64  ( FIGS. 4 and 5 ), and to substantially minimize fastener movement and detachment from the cartridge. Of course, the slot may have different shapes and still falls within the scope of the invention. Barbs  70   a  and  70   b  are preferably attached to the distal end  46  of the elongate portion  38  at a position wherein slot  72  is in between barbs  70   a  and  70   b . In  FIG. 8 , another embodiment of the fastener preferably resembles the fastener embodiment shown in  FIG. 7  except that the barbs  70   a  and  70   b  are eliminated. The fastener embodiment includes an elongate portion  38  that defines a slot  72  configured to accommodate a cartridge protrusion (not shown). 
     Referring now to  FIG. 9 , multiple fasteners  26  may be used to attach the developer roller housing  24  to the toner hopper  22 . For instance, one fastener  26   a  may be used to attach the developer roller housing  24  to the toner hopper  22  at a first corner, and another fastener  26   b  may be used at a second corner. Adhesive tapes (not shown) may be used to further support the attachment of the developer roller housing  24  to the toner hopper  22 . The adhesive tapes may be positioned along the developer roller housing rail  66  and the toner hopper rail  68 . 
     It can be appreciated that the present invention provides an alternative to ultrasonically welding back cartridge pieces during remanufacturing. The present invention provides an alternative that is more cost effective than ultrasonic welding and that allows cartridges to be remanufactured faster and with less tooling involved. Although the description above contains many specifications, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. For example, the shapes of the fastener main body  28  and elongate portion  38  may vary. The fastener may be used to join printer cartridge parts other than the developer roller housing and the toner hopper. The invention is capable of other embodiments and of being practiced and carried out in various ways. The invention is not limited in its application to the details of the construction and to the arrangement of the components set forth in the above description or as illustrated in the drawings.