Abstract:
A user-removable stabilizer for a toner cartridge assembly comprises of at least one member that becomes inserted in the toner cartridge assembly for capturing a first movable section of the toiler cartridge assembly and interconnecting at least the first movable section with a second movable section of the toner cartridge assembly, and a stopping member protruding upwardly from the at least one member for limiting insertion of the stabilizer into the toner cartridge assembly. A method of stabilizing movable sections of a toner cartridge assembly is also provided.

Description:
FIELD OF THE INVENTION 
   The present invention generally relates to the field of removable cartridge assemblies for electrophotographic image forming devices. More specifically, it relates to a stabilizer for interconnecting two movable sections of a toner cartridge assembly. A method for stabilizing movable sections of a toner cartridge assembly is also contemplated. 
   BACKGROUND OF THE INVENTION 
   Electrophotographic image forming devices (“EP devices”), such as photocopiers, laser printers, and facsimile machines, may employ the use of removable toner cartridge assemblies. Such cartridge assemblies are removable because the serviceable lifetime of certain cartridge components is often shorter than the serviceable lifetime of the EP device that the cartridge supplies. Cartridge assemblies for these image forming devices often include a photoconductive drum and a developer housing located adjacent to the photoconductive drum for the purpose of providing toner. The toner is often housed in a molded plastic reservoir. The cartridge assembly also may include a toner adder roller, a charge roller, a doctor blade, and a gear train that mates to a set of gears in the EP device. The gears are used, among other things, to drive the photoconductive drum in conjunction with the toner adder roller. A waste toner reservoir may also be attached to one side of the cartridge. Toner cartridges may be supplied to a user in a conventional all inclusive assembly or in a separable multi-part assembly. 
   In recent years, the size of the image forming device has become a significant issue. For instance, with regard to laser printers, demands of desk space in the digital office have dictated the reduction in size of the printers. Size restrictions, both in regard to desktop space, and in shipping costs have limited the overall size of the corresponding toner cartridge. For this reason, it has become advantageous to both manufacturer and user of the EP device in many cases to split apart the toner storage component of the cartridge from the image forming housing component of the cartridge. Generally, the image forming component of the cartridge contains the photoconductor drum, while the toner storage component of the cartridge contains the toner. These so called two-part toner cartridges provide the user a longer service life of key components of the cartridge, while limiting the space required for toner storage within the image forming device. 
   For larger office image forming systems, desktop space is not the issue. However, a two-part cartridge can still have various benefits. For instance, the photoconductive drum and toner can be separated, such that if the photoconductor drum section is damaged, toner may be spared. Likewise, if toner usage is great, the photoconductive drum may be used in more than one toner container cycle. 
   Cartridges of the two-part variety are used today to provide toner to both monochrome and color EP devices. For instance, in color laser printers, the number of cartridges is increased due to the additional toner requirements for producing the large array of colors needed in color image forming print jobs. For example, while monochrome laser printing requires a single cartridge of black toner, a color laser printer will require four cartridges such as a black, magenta, cyan, and yellow. 
   One problem sometimes encountered in two-piece cartridges relates to damage during shipping. Specifically, movement of the cartridge components during shipping can create cartridge failure. This failure is often associated with breakage of the cartridge housing and massive toner leakage. Such failure can ultimately deem the shipped cartridge unusable by the user. Obviously, this creates additional cost for the manufacturer relating to replacement of the damaged cartridge, as well as delay in delivering a usable cartridge to the user. 
   Several options have been contemplated for minimizing movement of components of the two-piece cartridge. One option relates to including additional packing material around the cartridge. However, packaging methods that add bulk, such as adding cushioning to the shipping material, are not desirable due to the significant added cost of the shipping material and the relatively insignificant improvement of such methods. Likewise, additional holding methods of conventional packaging materials such as cardboard, STYROFOAM blocks, plastic shipping trays, and the like, are not feasible due to their relative ineffectiveness in preventing movement and subsequent breaks in the cartridges during shipping. Furthermore, additional packaging bulk material creates greater complexity and frustration for the end user to remove the material and dispose of the same. 
   Accordingly, the need exists for a device and method for minimizing cartridge damage during movement of the cartridge. The device would allow for simple assembly by an individual or machine and disassembly by the end-user. The device would be relatively easy to form and low cost. 
   SUMMARY OF THE INVENTION 
   In accordance with one aspect of the invention, a user-removable stabilizer for a toner cartridge assembly is disclosed. The stabilizer may include at least one member that becomes inserted in the toner cartridge assembly for capturing a first movable section of the toner cartridge assembly and interconnecting at least the first movable section with a second movable section of the toner cartridge assembly. 
   In one embodiment, the stabilizer is keyed to be received by a keyway of the toner cartridge assembly. The at least one member of the stabilizer may include two prongs and the prongs may included inclined faces. The stabilizer may also include a clip that engages the toner cartridge assembly when the stabilizer becomes inserted in the toner cartridge assembly. The stabilizer may also include a cap that engages the toner cartridge assembly when the stabilizer becomes inserted in the toner cartridge assembly. 
   Also, the stabilizer may include an ejector that assists with expelling the stabilizer in the event a user attempts to insert the toner cartridge assembly into an electrophotographic device when the stabilizer is inserted in the toner cartridge assembly. The stabilizer may include a stop for preventing insertion of the toner cartridge assembly into an electrophotographic device when the stabilizer is inserted in the toner cartridge assembly. 
   Furthermore, the stabilizer may include at least one tab for facilitating insertion and removal of the stabilizer. In one embodiment, the stabilizer includes a main body portion formed from an elongated beam terminating in the at least one member. The stabilizer may also include a main body portion having a curved surface defining a housing and the at least one member is positioned within the housing. 
   In accordance with a second aspect of the invention, a toner cartridge assembly is disclosed. The toner cartridge assembly includes a first movable section, a second movable section, a keyway, and a user removable stabilizer including at least one member that is keyed to engage the keyway, wherein the stabilizer interconnects the first and second movable sections. In one embodiment, a portion of the first and second movable sections form the keyway. The stabilizer may include at least two projecting members separated by a gap that form the key to engage the keyway. Also, the at least two projecting members may comprise prongs with inclined faces. The stabilizer may include a stop for preventing insertion of the stabilizer into an electrophotographic device when the stabilizer is inserted in the toner cartridge assembly. The stabilizer may also include an ejector that assists with expelling the stabilizer in the event a user attempts to insert the toner cartridge assembly into an electrophotographic device when the stabilizer is inserted in the toner cartridge assembly. At least one tab may be provided for facilitating insertion and removal of the stabilizer. 
   In another embodiment, the toner cartridge assembly includes first and second removable stabilizers. Each stabilizer interconnects at least two movable portions of a toner cartridge assembly and at least one of the first and second removable stabilizers includes a stop for preventing insertion of the toner cartridge assembly into an electrophotographic device when the stabilizer is attached to the toner cartridge assembly. 
   The other of the at least one of the first and second removable stabilizers may have an ejector that assists with expelling the stabilizer in the event a user attempts to insert the toner cartridge assembly into an electrophotographic device when the stabilizer is inserted in the toner cartridge assembly. At least one of the first and second removable stabilizers may include a member that becomes inserted in the toner cartridge assembly for interconnecting the at least two movable sections of the toner cartridge assembly. Also, at least one of the first and second removable stabilizers may be keyed to engage a keyway formed by the at least two movable portions of the toner cartridge assembly. In one embodiment, each of the first and second removable stabilizers include two prongs separated by a gap that form the key to engage the keyway. Also, each of the first and second removable stabilizers may include a clip that engages the toner cartridge assembly and minimizes vertical movement of the stabilizers. Each of the first and second removable stabilizers may also include a tab for facilitating insertion and removal of the stabilizers. 
   In accordance with a third aspect of the invention, a method of stabilizing movable sections of a toner cartridge assembly is disclosed. The method comprises attaching two stabilizers to the toner cartridge assembly, such that the stabilizers interconnect at least two movable sections of the toner cartridge assembly. In one embodiment, the attaching comprises inserting a member of the first stabilizer in a first end of the toner cartridge assembly and inserting a member of the second stabilizer in a second end of the toner cartridge assembly. The method may also comprise the step of providing an ejector on one of the first and second stabilizers to assist with expelling the stabilizer in the event a user attempts to insert the toner cartridge assembly into an electrophotographic device when the stabilizer is inserted in the toner cartridge assembly. The method may also comprise the step of providing a stop on one of the first and second stabilizers for preventing insertion of the toner cartridge assembly into an electrophotographic device when the stabilizer is attached to the toner cartridge assembly. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention. In the drawings: 
       FIG. 1   a  is a perspective view of a representative cartridge assembly in accordance with one possible embodiment of the present invention disclosed herein; 
       FIG. 1   b  is an elevational view of a cleaner side of the cartridge assembly  FIG. 1   a;    
       FIG. 1   c  is an elevational view of a drive side of the cartridge assembly of  FIG. 1   a;    
       FIGS. 2   a  and  2   b  are perspective views of a toner cartridge assembly showing insertion of a stabilizer of the present invention; 
       FIGS. 3   a  and  3   b  are perspective views a first embodiment of a stabilizer of the present invention; 
       FIG. 4  is a cutaway side view of a representative electrophotographic image forming device of the present invention; 
       FIGS. 5   a  and  5   b  are perspective views of a second embodiment of a stabilizer of the present invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustrations, specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention and like numerals represent like details in the various figures. Also, it is to be understood that other embodiments may be utilized and that process, mechanical and/or other changes may be made without departing from the scope of the present invention. In accordance with the present invention, a stabilizer for a cartridge assembly and related method are hereafter described. 
     FIGS. 1   a - 1   c  illustrate a representative cartridge assembly, such as a toner cartridge assembly  10  for an electrophotographic image forming device (“EP device”) that may utilize one embodiment of the stabilizer of the present invention. As previously mentioned, many of these cartridge assemblies  10  are formed in a multi-part arrangement, wherein at least a first section S 1  and second section S 2  are movable in relation to one another. For instance, the toner storage component of the assembly may be separable from the image forming housing component. However, other components of the cartridge assembly may be movable in relation to one another. The present invention removably attaches to the cartridge assembly to minimize movement or otherwise stabilize certain movable components of the assembly during transport or other movement of the cartridge assembly. In one embodiment, shown in  FIG. 2   a , the attachment includes inserting at least a portion of the stabilizer  12  into the toner cartridge assembly  10 . As shown, the insertion requires the user to direct the stabilizer  12  in the direction Y 1  until it engages the toner cartridge assembly  10 .  FIG. 2   b  shows the stabilizer  12  fully inserted in the toner cartridge assembly. 
   Further describing the details of the toner cartridge assembly  10 , it may include a cleaner side  14  ( FIG. 1   b ) and a drive side  16  ( FIG. 1   c ). The cleaner side  14  may include a housing  18  that receives waste toner. As shown, the housing  18  includes a receiver  20   a  that receives a projection or post  22   a  from a first section S 1  of the toner cartridge assembly  10 . The first section S 1  may comprise the toner storage component of the cartridge assembly  10 . 
   Turning to  FIG. 1   c , the drive side  16  includes a gear assembly  26  that facilitates part of the image transfer process for the EP device. This process of image forming is well known and not discussed further herein. Similar to the housing  18  of the cleaner side  14 , the drive side  16  includes a receiver  20   b  that receives a projection or post  22   b  from the first section S 1  of the toner cartridge assembly  10 . The post  22   b  may move within the receiver  20   b , which provides a certain freedom of the cartridge components that may be desirable after the cartridge assembly  10  becomes installed in the EP device or when separating sections of a multi-part cartridge assembly  10 . 
   In one embodiment, the posts  22   a ,  22   b  have a vertical member  28  crossed with a horizontal member  30 , thereby substantially forming a “t-shape.” The receivers shown have a substantially arched surface that receives the t-shaped post  22   a ,  22   b . The combination of the posts  22   a ,  22   b  and the receivers  20   a ,  20   b  create a keyway  34  for receiving a keyed portion of the stabilizer  12 , as discussed below in further detail. As previously discussed in the Background, during movement of the toner cartridge assembly (such as during shipping), the post  22   a ,  22   b  and its connected structure may deleteriously move in relation to the receiver and its connected structure. This may result in fracture of a component of the cartridge assembly  10 , thereby rendering the cartridge unusable. However, as previously mentioned, movement of the post  22   a ,  22   b  within the receiver  20   a ,  20   b , may be desirable after the cartridge assembly  10  becomes installed in the EP device or when separating sections of a multi-part cartridge assembly  10 . The stabilizer  12  of the present invention serves to stabilize or minimize movement of sections (e.g., S 1 , S 2 ) of the cartridge assembly  10  during movement (such as during shipping of the cartridge assembly  10 ), but is removable to allow desired movement of the sections S 1 , S 2  after movement of the cartridge assembly  10 . 
   In a first embodiment shown in  FIGS. 3   a  and  3   b , the stabilizer  12  includes a main body portion  36  formed from an elongated beam  38  having a longitudinal axis X 1 . One end of the beam  38  terminates in at least one projecting member, such as the prongs  40  shown. The prongs  40  include inclined faces  42  that assist with installation of the stabilizer  12 . For instance, the inclined faces  42  form a ramp that initially loosely engages the post  22   a ,  22   b  and transitions to a tighter fit as the user further inserts the stabilizer  12 . Although two prongs  40  with inclined faces  42  are shown, the stabilizer  12  may include one or any number of projecting member(s) with any profile. Also, the prongs  40  may be any length, but would preferably have a length L 1  in the direction of the axis X 1  less than or equal to a length L 2  of the post  22   a ,  22   b  (see  FIG. 1   a ). Preferably, the projecting member(s) would be “keyed,” such that they would permit insertion into the keyway  34  formed by the posts  20   a ,  20   b  and receivers  18   a ,  18   b . For instance, a gap  44  separates the two prongs  40  shown in  FIG. 3   a , such that insertion of the stabilizer  12  results in the vertical member  26  of the t-shaped post  20   a ,  20   b  becoming positioned in the gap  44  between the prongs  40 . Capturing the vertical member  26  helps to minimize rotational and vertical movement of the post within the receiver  18   a ,  18   b.    
   At the junction of the prongs  40  and the main body portion  36 , the stabilizer  12  includes a cap  46 . As shown, a vertical wall  48  and horizontal wall  50  form the cap  46 , such that it extends at least partially over the prongs  40 . The vertical wall  48  provides a stop for limiting the distance the stabilizer may become inserted in the cartridge assembly  10 , while the horizontal wall  50  assists with minimizing vertical movement and rotation of the stabilizer when installed. In other words, as the user inserts the prongs  40  into a portion of the cartridge assembly  10 , the vertical wall  48  engages a portion of the cartridge assembly  10  and prevents further insertion, as seen in  FIG. 2   b . Preferably, the cap  46  contacts a portion of the cartridge assembly  10 , which further limits vertical movement of the stabilizer  12  with relation to the cartridge assembly  10 . Although described as being positioned at the junction of the prongs  40  and the main body portion  36 , the cap  46  may be positioned anywhere on the stabilizer  12 . 
   The end of the beam  38 , opposite the at least one projecting member, includes a clip  52 . The clip  52  may comprise various structures that serve to further engage the cartridge assembly  10  when installed. In the present embodiment, the clip  52  has a curved member projecting from the beam  38 , thereby forming a hook. As shown in  FIG. 2   b , the clip  52  captures a portion P of the cartridge assembly  10 . This capturing assists with minimizing vertical movement of the stabilizer  12  because the portion P of the cartridge assembly  10  becomes substantially fixed within the clip  52 . 
   Once inserted ( FIG. 2   b ), the stabilizer interconnects the first section S 1  and second section S 2  of the cartridge assembly  10  having one of the posts  22   a ,  22   b  and one of the receivers  20   a ,  20   b . This interconnection minimizes relative movement, such as any vertical, horizontal, rotational, or other movement, of the sections S 1 , S 2  with relation to each other. During movement of the cartridge assembly  10 , such as during shipping, the interconnection of the sections S 1  and S 2  prevents either section from moving in a manner that would result in fracture. Instead, the stabilizer  12  substantially rigidly holds the sections S 1  and S 2  together, thus minimizing damage to the cartridge assembly  10 . One will appreciate that this embodiment of the stabilizer has a substantially horizontal configuration when inserted in the cartridge assembly  10 . Also, a portion of the stabilizer  12 , such as a portion of the clip  52  or the main body portion  36 , may extend beyond the boundary of the cartridge assembly  10  when inserted. For instance, as shown in  FIG. 2   b , a portion of the stabilizer  12  extends beyond an outer surface OS of the cleaner side  14 . Alternatively, the stabilizer  12  may be substantially flush with the cartridge assembly  10  or fully recessed within the boundary of the cartridge assembly  10  when inserted. 
   It is intended that the user would remove the stabilizer  12  from the cartridge assembly  10  prior to insertion of the cartridge assembly  10  into the EP device. This removal may be accomplished by simply pulling a part of the stabilizer  12  in a direction Y 2  ( FIG. 2   a ) away from the cartridge assembly  10 . However, the stabilizer  12  may also include an ejector  56  or other structure that expels the stabilizer  12  from the cartridge assembly  10  in the event a user attempts to insert the toner cartridge assembly  10  into the EP device with the stabilizer still attached. In other words, the ejector  56  comprises an elongated member  58  extending substantially transverse to the longitudinal axis X 1  of the beam. In this arrangement, as a user inserts the cartridge assembly  10  with the stabilizer  12  of the present embodiment into the EP device, a portion of the EP device, such as a support rail  60  ( FIG. 4 ), may engage the ejector  56 . As the user continues to insert the cartridge assembly  10 , the support rail  60  prevents insertion of the stabilizer  12  and expels the stabilizer  12  from the cartridge assembly  10 . Although shown in this embodiment as being positioned adjacent to the cap, the ejector may be located anywhere on the stabilizer  12  to force a situation that causes the stabilizer  12  to become expelled when it engages a structure on the EP device. 
   To facilitate insertion and/or removal of the stabilizer  12  into and out of the cartridge assembly  10 , the stabilizer  12  may include one or more tabs  62 . The tab  62  provides a point for the user to engage with his or her fingers to remove the stabilizer by pulling in the direction of the longitudinal axis X 1 . Although the tab  62  may be positioned anywhere on the stabilizer  12 , it would preferably be located at a point easily accessible by the user when the stabilizer  12  is inserted in the cartridge assembly  10 . As shown, this may result in the tab  62  being positioned near an edge  64  of the stabilizer  12 . 
     FIGS. 5   a  and  5   b  illustrate a second embodiment of the stabilizer  12 . Instead of the substantially horizontal installed configuration of the first embodiment, this embodiment has a substantially vertical configuration when installed. As shown, the main body portion  36  includes a curved surface  66  defining a housing  68 . In one embodiment, the housing  68  includes an archway  68   a  having a profile similar to a profile of the arched surface of the receivers  20   a,   20   b . These similar profiles enable the archway  68   a  to become positioned over the arched surface of the receivers  20   a ,  20   b . Within the housing  68 , the stabilizer  12  includes at least one projecting member, such as the prongs  40  previously discussed. Again, while two prongs  40  with inclined faces  42  are shown, the stabilizer  12  may include one or any number of projecting member(s) with any profile. 
   With specific reference to  FIG. 5   a , the stabilizer  12  may also include one or more projecting member(s)  70   a ,  70   b  extending in a vertical direction, substantially transverse to a longitudinal axis X 2  of the prongs  40 . As shown, the stabilizer  12  includes two substantially parallel, vertical projecting members  70   a ,  70   b  extending from the top of the curved surface  66  of the main body  36 . In this arrangement, one of the vertical projecting members  70   a ,  70   b  includes a second embodiment of the clip  52 . In the present embodiment, the clip  52  has a curved member projecting from the vertical projecting member  70   a , thereby forming a hook. As previously discussed, the clip  52  minimizes vertical movement of the stabilizer  12  when installed. 
   The other of the vertical projecting members  70   b  includes a stop  72  for preventing insertion of the stabilizer  12  into the EP device and thereby informing the user to remove the stabilizer  12 . In one embodiment, the stop  72  takes the form of a wall  74  extending from a portion of the projecting member  70   b . Although the wall  74  may have any dimensions, as shown, it extends approximately half the length L of the vertical projecting member  70   b . If a user attempts to insert a cartridge assembly  10  into EP device with the present embodiment of the stabilizer  12  installed, the wall  74  will engage a portion of the EP device. For instance, the support rail  60  ( FIG. 4 ) or other structure may engage the wall  74 , thereby providing resistance as the user attempts to insert the cartridge assembly. Noting this resistance, the user will remove the stabilizer  12 , thereby permitting easy installation of the cartridge assembly. The stabilizer  12  may have one or more tabs  62  to facilitate with the removal of the stabilizer  12 . As previously discussed, the tabs  62  provide a point for the user to engage with his or her fingers to remove the stabilizer by pulling in the direction of the axis X 2 . In the present embodiment, the stabilizer  12  includes two tabs  62  symmetrically positioned on the curved surface  66  defining the housing  68 . 
   Although a cartridge assembly  10  may only have a single stabilizer  12 , multiple stabilizers  12  may simultaneously be used. For instance, a stabilizer  12  having a stop  72  may become inserted into a leading edge LE ( FIG. 2 ) of the cartridge assembly  10  (i.e., the edge that would be the first inserted into the EP device), while a stabilizer  12  having an ejector  56  may become inserted into an opposite or trailing edge TE of the cartridge assembly  10 . Obviously, utilizing two or more stabilizers  12  enables a user to interconnect multiple sides of the cartridge sections S 1  and S 2 , thereby further minimizing movement versus use of a single stabilizer alone. 
   The present invention presents a stabilizer  12  for a toner cartridge assembly  10  that minimizes movement of cartridge sections S 1 , S 2 , thereby minimizing cartridge  10  damage during movement of the cartridge  10 . The stabilizer  12  allows for simple attachment and removal from the cartridge assembly  10 . 
   The foregoing discussion was chosen to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications suited to the particular use contemplated. Instead of the one-piece stabilizers  12  disclosed, the stabilizer may be multiple pieces. The stabilizer  12  may be formed from casting, welding, or otherwise. Preferably, the stabilizer  12  would be formed from a polymer material, such as acrylonitrile butadiene styrene (ABS), polypropylene, or other. Also, the stabilizers  12  would preferably be formed from a bright color, such as red, to capture the user&#39;s attention. In one embodiment, the stabilizer  12  is at least partially in a color different than the color of the first and second movable sections S 1 , S 2 . For instance, the stabilizer may be partially or fully the color red, while the first and second movable sections S 1 , S 2  are black or gray. The stabilizer  12  may be formed in this color (e.g., by molding) or color maybe added to a formed stabilizer  12 . Alternatively, or in addition to the bright color, the stabilizer  12  may also have a sticker or removable “flag” to attract the user&#39;s attention and remind the user to remove the stabilizer  12  prior to insertion of the cartridge assembly  10  into the EP device. Instead of the sticker or removable flag, the stabilizer  12  may be formed with a permanent directional symbol, such as an arrow  76  indicating a direction for insertion and/or removal of the stabilizer  12 . Although the term “cartridge assembly” or “toner cartridge assembly” are used throughout this specification, a skilled artisan will appreciate that the stabilizer may be used with any supply item of an EP device. All modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.