Abstract:
A method presently disclosed provides a first portion of a housing containing at least one protrusion, removes at least a portion of the at least one protrusion, and couples a first material with a second portion of the housing.

Description:
FIELD 
       [0001]    The present invention relates generally to the field of toner cartridges. 
       BACKGROUND 
       [0002]      FIG. 1  depicts an image forming apparatus  100  know in the art. The image forming apparatus  100  may be color and/or black-and-white copiers, color and/or black-and-white printers, and/or so-called “all-in-one devices” that incorporate two or more functions such as scanning, copying, printing, and faxing capabilities in one device. 
         [0003]    The image forming apparatus  100  is configured to accept replaceable printer cartridge  10  containing toner for generating images. As known in the art, the printer cartridge  10  comprise one or more guide keys/protrusions  20  configured to be inserted in to one or more guide channels  30  within the image forming apparatus  100 . 
         [0004]    As known in the art, when image forming apparatus manufacturer designs/updates/manufactures a new model image forming apparatus, they may change the location, width, and/or depth of the guide channels  30 . These types of changes to the image forming apparatus may force cartridge manufacturers to change location and/or shape of the guide keys/protrusions  20  to accommodate the changes made to the channels  30 . This redesign prevents users from using their unused cartridges in the new image forming apparatus. Similarly, any remanufactured cartridge configured to be used with the old image forming apparatus would have to be discarded because it could not be accommodated by the redesigned image forming apparatus. 
         [0005]    To avoid waist and pollution, a need exist for a process and associated apparatus to allow cartridges originally designed for one image forming apparatus to be used by another image forming apparatus. 
       SUMMARY 
       [0006]    According to a first aspect of the present disclosure, a method is disclosed, the method comprising: providing a first portion of a housing comprising at least one protrusion; removing at least a portion of the at least one protrusion; and coupling a first material with a second portion of the housing. 
         [0007]    According to a second aspect of the present disclosure, a method is disclosed, the method comprising: providing a housing for a toner cartridge configured to accommodate a first image forming apparatus; removing at least a portion of the housing, and coupling a first material with the housing to allow the toner cartridge to accommodate a second image forming apparatus. 
         [0008]    According to a third aspect of the present disclosure, a housing is disclosed, the housing comprising: a portion of a first protrusion configured to accommodate a first image forming apparatus; and a second protrusion configured to accommodate a second image forming apparatus. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0009]      FIG. 1  depicts an image forming apparatus as known in the prior art. 
           [0010]      FIG. 2  depicts another image forming apparatus as known in the prior art. 
           [0011]      FIG. 3  depicts the image forming apparatus shown in  FIG. 2  with modified channels. 
           [0012]      FIG. 4  depicts the image forming apparatus shown in  FIG. 3  and modified toner cartridge according to the present disclosure. 
           [0013]      FIG. 5  depicts the image forming apparatus shown in  FIG. 3  and modified toner cartridge according to the present disclosure. 
           [0014]      FIG. 6  depicts the image forming apparatus shown in  FIG. 3  and modified toner cartridge according to the present disclosure. 
           [0015]      FIG. 7  depicts the image forming apparatus shown in  FIG. 3  and modified toner cartridge according to the present disclosure. 
           [0016]      FIG. 8  depicts a portion of a toner cartridge as known in the prior art. 
           [0017]      FIGS. 9-10  depict modified portion of a toner cartridge according to the present disclosure. 
           [0018]      FIGS. 11-14  depict a device according to the present disclosure. 
           [0019]      FIGS. 15-18  depict another device according to the present disclosure. 
           [0020]      FIGS. 19-20  depict another image forming apparatus as known in the prior art. 
           [0021]      FIGS. 21-22  depict the image forming apparatus shown in  FIG. 20  with modified keying features. 
           [0022]      FIGS. 23-24  depict the image forming apparatus shown in  FIG. 21  and modified print cartridge according to the present disclosure. 
           [0023]      FIGS. 25-26  depict the image forming apparatus shown in  FIG. 22  and modified print cartridge according to the present disclosure. 
       
    
    
       [0024]    In the following description, like reference numbers are used to identify like elements. Furthermore, the drawings are intended to illustrate major features of exemplary embodiments in a diagrammatic manner. The drawings are not intended to depict every feature of every implementation nor relative dimensions of the depicted elements, and are not drawn to scale. 
       DETAILED DESCRIPTION 
       [0025]    In the following description, numerous specific details are set forth to clearly describe various specific embodiments disclosed herein. One skilled in the art, however, will understand that the presently claimed invention may be practiced without all of the specific details discussed below. In other instances, well known features have not been described so as not to obscure the invention. 
         [0026]      FIG. 2  depicts a toner cartridge  40  known in the art. The toner cartridge  40  may comprise one or more guide keys/protrusions  50  configured to guide the toner cartridge  40  into an image forming apparatus  110  using channels  60 . As known in the art, the one or more guide keys/protrusions  50  may be positioned on end caps(s) of the toner cartridge  40  or may be positioned on other outer parts of the housing defining the toner cartridge  40 . 
         [0027]      FIG. 3  depicts an image forming apparatus  120  comprising channels  70  that are narrower than the channels  60  of the image forming apparatus  110 . If one skilled in the art attempts to install the toner cartridge  40  into the image forming apparatus  120 , they would fail because channels  70  cannot accommodate the guide keys/protrusions  50 . 
         [0028]    In one exemplary embodiment according to the present disclosure, the one or more guide keys/protrusions  50  associated with the toner cartridge  40  may be at least partially removed, replaced, modified and/or moved to another location to allow the toner cartridge  40  to be compatible with the image forming apparatus  120 . 
         [0029]    In one exemplary embodiment, the one or more guide keys/protrusions  50  may be completely or partially removed from the toner cartridge  40  as shown in  FIG. 4 . Although not shown, the removal of the one or more guide keys/protrusions  50  may leave behind an opening/hole (not shown) where the one or more guide keys/protrusions  50  used to be. Once the one or more guide keys/protrusions  50  are removed, new guide keys/protrusions may be provided to allow the toner cartridge  40  to enter the image forming apparatus  120  with channels  70 . In one exemplary embodiment, one or more new guide keys/protrusions  80  may be provided to accommodate the channels  70  as shown in  FIG. 5 . The one or more new guide keys/protrusions  80  may be glued, welded, coupled or fused to a portion of the toner cartridge  40  and aligned with the channels  70 . Because the guide keys/protrusions  80  are configured to accommodate the channels  70 , the toner cartridge  40  may be utilized/accommodated by the image forming apparatus  120 . 
         [0030]    In another exemplary embodiment, the one or more guide keys/protrusions  50  removed from the toner cartridge  40  may be re-used to accommodate the channels  70  as shown in  FIG. 6 . The one or more guide keys/protrusions  50  may be glued, welded, coupled or fused to a portion of the toner cartridge  40  and aligned with the channels  70 . By repositioning and/or aligning the guide keys/protrusions  50 , the toner cartridge  40  may be utilized/accommodated by the image forming apparatus  120 . 
         [0031]    In another exemplary embodiment, one or more new guide keys/protrusions  90  may be provided to accommodate the channels  70  as shown in  FIG. 7 . The guide keys/protrusions  90  may be substantially similar in shape and/or size to the removed guide keys/protrusions  50 . The one or more new guide keys/protrusions  90  may be glued, welded, or fused to a portion of the toner cartridge  40  and aligned with the channels  70 . Because the guide keys/protrusions  90  are configured to accommodate the channels  70 , the toner cartridge  40  may be utilized/accommodated by the image forming apparatus  120 . 
         [0032]    Different techniques may be applied to remove at least a portion of the guide keys/protrusions  50 . In one exemplary embodiment, at least a portion of the guide keys/protrusions  50  may be removed using a blade and/or a knife. In another exemplary embodiment, at least a portion the guide keys/protrusions  50  may be removed using pliers to break at least a portion the guide keys/protrusions  50  off the toner cartridge  40 . In another exemplary embodiment, at least a portion the guide keys/protrusions  50  may be removed using a saw, a laser and/or water-jet. 
         [0033]    As known in the art, an image forming apparatus may comprise a detection sensor (not shown) and/or detection circuit (not shown) configured to detect that a toner cartridge has been properly installed in the image forming apparatus. To activate the detection sensor/circuit, the toner cartridges may comprise one or more activation tabs/protrusions (not shown) configured to interact/activate the detection sensor/circuit. As the image forming apparatus is redesigned and/or changed by the manufacturer, the detection sensor/circuit may be repositioned and/or changed. When that occurs, the manufacturers of the toner cartridge may have to re-design the toner cartridges and/or the activation tab to accommodate the new image forming apparatus. As known in the art, the activation tab(s) may be positioned on end caps(s) of the toner cartridge or may be positioned on other outer parts of the housing defining the toner cartridge. 
         [0034]    In one exemplary embodiment according to the present disclosure, the one or more activation tabs associated with a particular toner cartridge may be at least partially removed, replaced, and/or moved to another location to accommodate the changes in the image forming apparatus and allow interaction with the detection sensor/circuit. 
         [0035]      FIG. 8  depicts an end cap  150  known in the art from a toner cartridge (not shown) configured to accommodate an image forming apparatus. The end cap  150  may comprise an activation tab  155 . In an exemplary embodiment, the activation tab  155  may be at least partially removed, repositioned, and/or replaced to accommodate another image forming apparatus. 
         [0036]    In one exemplary embodiment, at least a portion of the activation tab  155  may be removed from its original position  160  as shown in  FIG. 9 . In one exemplary embodiment, the removal of the activation tab  155  may leave behind an opening  165 . In an exemplary embodiment, the activation tab  155  may be coupled back to the end cap  150  at a position  170  as shown in  FIG. 10 . The activation tab  155  may be glued, welded, or fused to the end cap  150 . 
         [0037]    In an exemplary embodiment, the activation tab  155  may be replaced with another activation tab with different outer dimension(s). In another exemplary embodiment, the activation tab  155  may be replaced with another activation tab with similar outer dimension(s). 
         [0038]    Different techniques may be applied to remove at least a portion of the activation tab  155 . In one exemplary embodiment, at least a portion of the activation tab  155  may be removed using a blade and/or a knife. In another exemplary embodiment, at least a portion the activation tab  155  may be removed using pliers to break at least a portion the activation tab  155  off the end cap  150 . In another exemplary embodiment, at least a portion the activation tab  155  may be removed using a saw, a laser and/or water-jet. 
         [0039]    In one exemplary embodiment, a protrusion removal device  180  may be used to remove the activation tab  155  as shown in  FIG. 11 . The device  180  may comprise a holding platform  185  configured to accommodate the end cap  150  with the activation tab  155  facing down as shown in  FIGS. 11-12 . The device  180  may comprise a movable blade  190  configured to move from a resting position to a second position and back to the resting position along a direction shown by arrow  195 . In one exemplary embodiment, the blade  190  may be moved by an air piston (not shown) that is activated by a switch (not shown). 
         [0040]    In one exemplary embodiment, the end cap  150  may be placed on the holding platform  185  with the activation tab  155  facing the blade  190  as shown in  FIG. 12 . Activating the air piston (not shown) may move the blade  190  from it resting position (shown in  FIG. 12 ) to the second position (shown in  FIG. 13   a ) in the direction shown by arrow  195  thereby removing at least a portion of the activation tab  155  from the end cap  150 .  FIG. 13   b  depicts the blade  190  as it removes the activation tab  155 . The removed portion of the activation tab  155  may be allowed to fall into a holding compartment (not shown) located below the blade  190 . The blade  190  may be allowed to return to its resting position after removing a portion of the activation tab as shown in  FIG. 14 . 
         [0041]    In another exemplary embodiment, the blade  190  may remain in the stationary position and the end cap  150  may be moved from a resting position (not shown) to a secondary position (not shown) in the direction represented by arrow  195 . 
         [0042]    The device  180  may optionally comprise a holding arm  200  configured to hold the end cap  150  in place (not shown) during the removal of the activation tab  155 . 
         [0043]    In an exemplary embodiment, an alignment platform  210  may be used to align a new or a pre-cut activation tab  220  at the proper position and/or angle with the end cap  150  as shown in  FIGS. 15-16 . The platform  210  may comprise a plate  230  configured to accommodate the end cap  150  as shown in  FIG. 17 . The plate  230  may define an opening  240  configured to accommodate the new or pre-cut activation tab  220  as shown in  FIG. 16 . Position of the opening  240  depends on where the new or pre-cut activation tab  220  should be provided on the end cap  150 . 
         [0044]    The plate  230  may optionally define one or more opening  250 ,  255  configured to accommodate one or more protrusions  260 ,  270  associated with the end cap  150 . The plate  230  may optionally comprise a protrusion  275  configured to accommodate an opening  280  defined by the end cap  150 . 
         [0045]    In one exemplary embodiment, the new activation tab  220  may be ultrasonically welded to the end cap  150  using, for example an ultrasonic welding machine  280 . The ultrasonic welding machine  280  may be used to transmit vibrations at an ultrasonic frequency and pressure large enough to fuse or weld together the new activation tab  220  and the end cap  150 . In one exemplary embodiment, the new activation tab  220  may be welded to the end cap  150  using an automatic pneumatic ultrasonic machine (not shown). 
         [0046]    The plate  230  may optionally comprise a guide  290  configured to guide the welding machine  280  to the welding location of the new activation tab  220  and the end cap  150 . 
         [0047]    In another exemplary embodiment, the new activation tab  220  may be glued to the end cap  150 . In another exemplary embodiment, the new activation tab  220  may be coupled, or fastened by screw or other fastener to the end cap  150 . 
         [0048]    In one exemplary embodiment, the activation tab  220  is substantially same dimension as the activation tab  155 . In another exemplary embodiment, the dimensions of the activation tab  220  are different from the dimensions of the activation tab  155 . 
         [0049]    Referring to  FIG. 19 , as known in the art, color image forming apparatus  300  may comprise a frame  320  and a plurality of print cartridges  340  (one of which is shown for ease or reference). Each print cartridge  340  corresponds to a different color to be printed on the print medium. The frame  320  is configured to define a plurality of docking stations  360   a - d , with each docking station  360   a - d  corresponding to different print cartridge  340 . Each docking station  360   a - d  includes a mating keying feature  380   a - d  which only allows interconnection with a corresponding keyed print cartridge  340 . More particularly, each mating keying feature  380   a - d  at each docking station  360   a - d  is in the form of at least one recess which is configured with a geometric and/or positional constraint relative to a keying feature of a correspondingly keyed print cartridge  340 . Mating keying features  380   a - d  are shown in  FIG. 19 . 
         [0050]    The print cartridge  340  includes keying features/protrusions  400   a - b  which are different from keying feature(s) of the remaining print cartridges (not shown), and mates with the mating keying feature  380   d - e  at the docking station  360   d . More particularly, keying features  400   a - b  of the print cartridge  340  are in the form male tabs (as shown in  FIG. 20 ) which fit into corresponding female recesses defining the mating keying features  380   d - e.    
         [0051]    During installation, the print cartridge  340  is aligned at the station  360   d  and slid in into the color image forming apparatus  300 . Keying feature  400   a - b  in the form of the male tabs align with the mating keying features  380   d - e  in the form of the female recesses. Keying features/protrusions  400   a - b  thus fit within mating keying feature  380   d - e  at the station  360   d . In the event that the different print cartridge with a different keying feature corresponding to a different color toner is attempted to be installed at the station  360   d , the keying feature thereof defines a hard stop such that the print cartridge  340  cannot be installed at an improper docking station. 
         [0052]    As the color image forming apparatus  300  is redesigned and/or changed into an image forming apparatus  410 ,  440  by the manufacturer, the female recessed of the keying feature  380   d - e  may be repositioned (as shown in  FIGS. 21 ,  23 ) and/or have their shape changed (as shown in  FIG. 22 ). When that occurs, the manufacturers of the toner cartridge may have to re-design the toner cartridges and/or the keying features/protrusions  400   a  to accommodate the new color image forming apparatus  410 ,  440 . 
         [0053]    In one exemplary embodiment according to the present disclosure, at least the protrusion  400   a  associated with the print cartridge  340  may be at least partially removed, replaced, and/or moved to another location to accommodate the changes in the image forming apparatus. 
         [0054]    In one exemplary embodiment, the protrusion  400   a  may be removed to allow the print cartridge  340  to be inserted into the new color image forming apparatus  410  as shown in  FIG. 23 . In one exemplary embodiment, the removal of at least a portion of the protrusion  400  may create an opening (not shown) in the print cartridge  340 . The opening may be covered using, for example, a tape and/or plastic sheet. 
         [0055]    Different techniques may be applied to remove at least a portion of the protrusion  400   a . In one exemplary embodiment, at least a portion of the protrusion  400   a  may be removed using a blade and/or a knife. In another exemplary embodiment, at least a portion of the protrusion  400   a  may be removed using pliers to break at least a portion of the protrusion  400   a  off the print cartridge  340 . In another exemplary embodiment, at least a portion of the protrusion  400   a  may be removed using a saw, a laser and/or water-jet. 
         [0056]    Although the print cartridge  340  will fit the new color image forming apparatus  410  once at least a portion of the protrusion  400   a  is removed, in one exemplary embodiment another protrusion  420  (shown in  FIG. 24 ) may be provided to accommodate the keying feature  380   d  shown in FIGS.  21  and  23 - 24 . 
         [0057]    In one exemplary embodiment, the protrusion  420  may be glued, welded, coupled, fastened or fused to a portion of the print cartridge  340  and aligned with the keying feature  380   d . Because the protrusion  420  is configured to accommodate the keying feature  380   d , the print cartridge  340  may be prevented from being inserted into one of the other docking station  360   a - c.    
         [0058]    In an exemplary embodiment, the protrusion  420  may comprise different shape and/or dimensions from the removed protrusion  400   a . In another exemplary embodiment, the protrusion  420  may comprise substantially same shape and/or dimensions as the removed protrusion  400   a . In another exemplary embodiment, the removed protrusion  400   a  may be recycled and applied back to the print cartridge  340  as the protrusion  420 . 
         [0059]    In an exemplary embodiment, the protrusion  400   a  may be removed to allow the print cartridge  340  to be inserted into the new color image forming apparatus  440  as shown in  FIG. 25 . In one exemplary embodiment, the removal of at least a portion of the protrusion  400   a  may create an opening (not shown) in the print cartridge  340 . The opening may be covered using, for example, tape and/or plastic sheet. 
         [0060]    Different techniques may be applied to remove at least protrusion  400   a . In one exemplary embodiment, at least a portion of the protrusion  400   a  may be removed using a blade and/or a knife. In another exemplary embodiment, at least a portion of the protrusion  400   a  may be removed using pliers to break at least a portion of the protrusion  400   a  off the print cartridge  340 . In another exemplary embodiment, at least a portion of the protrusion  400   a  may be removed using a saw, a laser and/or water-jet. 
         [0061]    Although the print cartridge will fit the new color image forming apparatus  440  once the protrusion  400   a  is removed, in one exemplary embodiment another protrusion  450  (shown in  FIG. 26 ) may be provided to accommodate the keying feature  380   d  shown in FIGS.  22  and  25 - 26 . 
         [0062]    In one exemplary embodiment, the one protrusion  450  may be glued, welded, coupled, fastened or fused to a portion of the print cartridge  340  and aligned with the keying feature  380   d . Because the protrusion  450  is configured to accommodate the keying feature  380   d , the print cartridge  340  may be prevented from being inserted into one of the other docking station  360   a - c . In an exemplary embodiment, the protrusion  450  may comprise a shape configured to match the shape of the keying feature  380   d.    
         [0063]    Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings. 
         [0064]    While several illustrative embodiments of the invention have been shown and described, numerous variations and alternative embodiments will occur to those skilled in the art. Such variations and alternative embodiments are contemplated, and can be made without departing from the scope of the invention as defined in the appended claims. 
         [0065]    As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. The term “plurality” includes two or more referents unless the content clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosure pertains. 
         [0066]    The foregoing detailed description of exemplary and preferred embodiments is presented for purposes of illustration and disclosure in accordance with the requirements of the law. It is not intended to be exhaustive nor to limit the invention to the precise form(s) described, but only to enable others skilled in the art to understand how the invention may be suited for a particular use or implementation. The possibility of modifications and variations will be apparent to practitioners skilled in the art. No limitation is intended by the description of exemplary embodiments which may have included tolerances, feature dimensions, specific operating conditions, engineering specifications, or the like, and which may vary between implementations or with changes to the state of the art, and no limitation should be implied therefrom. Applicant has made this disclosure with respect to the current state of the art, but also contemplates advancements and that adaptations in the future may take into consideration of those advancements, namely in accordance with the then current state of the art. It is intended that the scope of the invention be defined by the Claims as written and equivalents as applicable. Reference to a claim element in the singular is not intended to mean “one and only one” unless explicitly so stated. Moreover, no element, component, nor method or process step in this disclosure is intended to be dedicated to the public regardless of whether the element, component, or step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. Sec. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for . . . ” and no method or process step herein is to be construed under those provisions unless the step, or steps, are expressly recited using the phrase “step(s) for . . . .”