Ergonomic toner cartridge

A toner cartridge with a handle formed centrally in a trailing end of the cartridge. The handle is dished to comfortably accept a hand and is adapted such that a user will recognize that said handle is dedicated to receiving the user's hand. The cartridge is therefore installed and removed without binding since the user's hand is centered as a result of the placement of the user's hand in said handle.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates, generally, to toner cartridges. More particularly, it relates to a toner cartridge that fits a large plurality of printers of differing brands and models.

2. Description of the Prior Art

Conventional toner cartridges are difficult to insert into a printer. No dedicated gripping surface is provided so most users simply grasp the trailing end of the waste bin and hopper in a haphazard manner. The plastic on the trailing end of the waste bin has a lattice work or open mesh structure and a user is expected to place his or her fingers through various narrow slots provided by such lattice work when lifting and installing the toner cartridge. The fingers of many people cannot fit between the minimal clearance between the waste bin handle and hopper, thereby making the handling of the toner cartridge difficult. Since the cartridge has no dedicated handle, the user will most likely grasp the cartridge off center and the weight of the hopper and waste bin together will cause the toner cartridge to tilt relative to a horizontal plane as the user attempts to insert the toner cartridge into the printer. The toner cartridge often jams as a result.

Thus, there is a need for a toner cartridge with a dedicated gripping means that centers a user's hands relative to the trailing end of the toner cartridge so that it can be placed into the printer while being held in a horizontal plane. Nor should an improved handle rely on narrow slots as part of the gripping means.

However, in view of the prior art considered as a whole at the time the present invention was made, it was not obvious to those of ordinary skill in the pertinent art how the identified needs could be fulfilled.

SUMMARY OF THE INVENTION

The long-standing but heretofore unfulfilled need for a toner cartridge that is adapted to engage a large number of printers made by different manufacturers and which also includes improvements that overcome the limitations of prior art toner cartridges is now met by a new, useful, and non-obvious invention.

The novel toner cartridge includes an improvement that enhances the ergonomics of a toner cartridge. A thumb grip, dished to accept a thumb, is formed in the trailing end of the waste bin, centrally thereof. An arch extends transversely across the trailing end of the waste bin and rises to a height sufficient to accommodate a user's fingers when the user's thumb is positioned in the thumb grip.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now toFIG. 1A, it will there be seen that the reference numeral10denotes an illustrative embodiment of the novel toner cartridge as a whole. Novel toner cartridge10is made by interconnecting waste bin12ofFIG. 1Bto hopper14ofFIG. 1Cto one another. More particularly, as suggested by the alignment of parts inFIGS. 1B and 1C, trailing end11of waste bin12is positioned over hopper14and said waste bin is then lowered until said two parts are interconnected. The details of how the interconnection is accomplished are disclosed more fully hereinafter.

As best understood in connection withFIGS. 2A-J, leading end13of waste bin12is sculpted so that it can mate with a plurality of families of printers manufactured by differing manufacturers.

Leading end13includes flat top wall15athat is disposed in a substantially horizontal plane when waste bin12is properly installed and flat vertical front wall15b.

InFIG. 2A, leading end recesses16a,16b, and16chaving a common size and configuration are formed in leading end13in equidistantly spaced relation to one another and in centered relation with respect to said leading end.

Each of the leading end recesses includes an arcuate back wall17a, flat vertical sidewalls17b, and a flat bottom wall17c. Two (2) outboard recesses having a common size and configuration16dand16eare formed in opposite ends of leading end13. Both of the outboard recesses include an arcuate back wall17ahaving less transverse extent than the respective arcuate back walls17aof the full recesses, one vertical flat wall17b, and a flat bottom wall17chaving less transverse extent than the respective flat bottom walls17cof the leading end recesses.

There may be other printer models that are accommodated by the novel universal toner cartridge of this invention and the invention is not limited to use with the printer models expressly listed herein. The above lengthy list of printer models is provided merely to establish the universal nature of the present invention.

FIGS. 1A and 1Bfurther depict the uppermost end of a first embodiment of an improved microswitch actuating tab19. Tab19is thicker (wider) and taller than the tabs heretofore known; note from saidFIGS. 1A and 1Bthat it is higher than the handle of waste bin12. Tab19, as best depicted inFIGS. 2B and 2D, is supported on the outboard side of its base by a structure19athat includes a horizontal wall supported at its leading and trailing ends by a pair of vertical walls as best depicted inFIG. 2B. The increased height ensures that tab19continues to function in its intended manner even when the hinges and latches of the printer have become worn. Support structure19ahelps prevent flexing and breakage of tab19by a misaligned printer door having worn hinges and latches.

InFIG. 2B, leading end recesses16a,16b,16cof theFIG. 1Aembodiment are merged together to create one elongate centered leading end recess18having flat back wall18a, arcuate walls18b,18bat opposite ends of said flat back wall, flat sidewalls18c,18c, and flat bottom wall18d. Outboard recesses16d,16eof theFIG. 2Aembodiment are retained in this second embodiment. A leading end sculptured in the manner ofFIG. 2Bmates with the printer models listed above in connection with the embodiment ofFIG. 2Aand with the above-mentioned printer models that may presently exist, or which may in the future be provided, that are not expressly included in said list.

InFIG. 2C, leading end recesses16a,16b,16c, and outboard recesses16d,16eof theFIG. 2Aembodiment are merged with one another to create step-shaped recess20that extends the entire transverse extent of leading end13of waste bin12. A leading end sculptured in the manner ofFIG. 2Cmates with the printer models listed above in connection with the embodiment ofFIG. 2Aand with the above-mentioned printer models that may presently exist, or which may in the future be provided, that are not expressly included in said list.

InFIG. 2D, outboard recess16dand leading end recesses16a,16bare merged together to form elongate recess21as are leading end recess16cand outboard recess16eof theFIG. 2Aembodiment to form recess22. A leading end sculptured in the manner ofFIG. 2Dmates with the printer models listed above in connection with the embodiment ofFIG. 2Aand with the above-mentioned printer models that may presently exist, or which may in the future be provided, that are not expressly included in said list.

The embodiment ofFIG. 2Eis attained by modifying the embodiment ofFIG. 2Aby merging together leading end recess16cand outboard recess16eto form recess22. Outboard recess16dand leading end recesses16aand16bof saidFIG. 2Aembodiment are unchanged. A leading end sculptured in the manner ofFIG. 2Emates with the printer models listed above in connection with the embodiment ofFIG. 2Aand with the above-mentioned printer models that may presently exist, or which may in the future be provided, that are not expressly included in said list.

The embodiment ofFIG. 2Fis attained by modifying the embodiment ofFIG. 2Aby merging together leading end recesses16aand16bthereby creating elongate recess23. Leading end recess16cand outboard recesses16dand16eof theFIG. 2Aembodiment are unchanged. A leading end sculptured in the manner ofFIG. 2Fmates with the printer models listed above in connection with the embodiment ofFIG. 2Aand with the above-mentioned printer models that may presently exist, or which may in the future be provided, that are not expressly included in said list.

The embodiment ofFIG. 2Gis attained by modifying the embodiment ofFIG. 2Aby merging together leading end recesses16band16c, thereby creating elongate recess24. Leading end recess16aand outboard recesses16d,16eof saidFIG. 2Aembodiment are unchanged. A leading end sculptured in the manner ofFIG. 2Gmates with the printer models listed above in connection with the embodiment ofFIG. 2Aand with the above-mentioned printer models that may presently exist, or which may in the future be provided, that are not expressly included in said list.

The embodiment ofFIG. 2His attained by modifying the embodiment ofFIG. 2Aby merging together outboard recess16dand leading end recess16a, thereby creating recess26, Leading end recesses16band16cand outboard recess16eare unchanged. A leading end sculptured in the manner ofFIG. 2Hmates with the printer models listed above in connection with the embodiment ofFIG. 2Aand with the above-mentioned printer models that may presently exist, or which may in the future be provided, that are not expressly included in said list.

The embodiment ofFIG. 2Iis attained by modifying the embodiment ofFIG. 2Aby merging together outboard recess16dand leading end recess16ato form recess26and by merging together leading end recesses16b,16c, and outboard recess16eto form elongate recess28. A leading end sculptured in the manner ofFIG. 2Imates with the printer models listed above in connection with the embodiment ofFIG. 2Aand with the above-mentioned printer models that may presently exist, or which may in the future be provided, that are not expressly included in said list.

The embodiment ofFIG. 2Jis attained by modifying the embodiment ofFIG. 2Aby merging together outboard recess16dand leading end recess16ato form recess26and by merging together leading end recess16cand outboard recess16eto form recess22. Leading end recess16bof theFIG. 2Aembodiment is unchanged. A leading end sculptured in the manner ofFIG. 2Jmates with the printer models listed above in connection with the embodiment ofFIG. 2Aand with the above-mentioned printer models that may presently exist, or which may in the future be provided, that are not expressly included in said list.

Returning now toFIG. 2A, it will there be seen that novel first circuit board mounting pad30is substantially larger than its prior art predecessors so that it can hold a circuit board having a width that is about twice the width of a common printer circuit board. (InFIGS. 17A and 17E, mounting pad30provides support for wide circuit board110a). Accordingly, wide circuit board110amates with a first group of printers that include contact pins that engage contacts111aand113apositioned on wide circuit board110ain position “30L” and it also mates with a second group of printers that include contact pins that engage contacts111aand113apositioned on wide circuit board110ain position “30R.”

Large circuit board mounting pad30also has sufficient size to accommodate a printer selector switch120or120a, disclosed hereinafter in connection withFIGS. 16A-C.

Second circuit board mounting port32is smaller than first circuit board mounting pad30. It mates with a third group of printers that include relatively small circuit boards that mate with mounting pads positioned near the front left edge of cleaner chamber12.

Older printer models such as Optra Se and Optra T have contact pins that mate with a circuit board positioned on mounting pad30and newer printer models such as Optra T520, Optra T522, Optra T620, Optra T622, and Optra T63X, have contact pins that mate with a circuit board mounted in circuit board port32. The Optra S models do not include a circuit board.

Still further novel features are perhaps best depicted inFIGS. 3A-F. Thumb grip34is formed in trailing end11of waste bin12, centrally thereof. It is dished to comfortably accept a thumb and a user will recognize that said thumb grip34is dedicated to receiving the user's thumb. The cartridge is installed and removed without binding when a user's hand is centered thereon due to placement of the user's thumb in said thumb grip34.

Moreover, as best indicated inFIGS. 3B and 3C, arch36extends transversely across trailing end11, rising to a height sufficient to accommodate a user's fingers when the user's thumb is positioned in thumb grip34. This structure ensures that toner cartridge10is held level when it is inserted into the printer. It also eliminates the narrow finger-receiving slots of the prior art.

A plurality of novel media guides, collectively denoted38inFIGS. 3A and 3C, are formed in a bottom wall of cleaner chamber12. Media guides38are shown in enlarged configuration inFIG. 3D. They have rounded surfaces as best understood in connection with saidFIG. 3Dto reduce the friction as paper is dragged over them. The reduced friction substantially eliminates the jamming problem caused by the high friction media guides of the prior art.

FIG. 3Cdepicts hopper torque tab receptacle40which is formed in cleaner chamber12. When cleaner chamber12is lowered vertically to engage hopper14, hopper torque tab43(FIG. 1C), is received within receptacle40. This keys hopper14to waste bin12, preventing lateral movement between said two parts when a driving force is applied to the hopper. More particularly, single-headed directional arrow42indicates the lateral direction hopper14is displaced when said hopper14is driven. Note that the plastic to the right of receptacle40, denoted41as a whole, provides reinforcement where it is most needed, i.e., in the direction of said arrow42. As best shown inFIG. 5A, a radius40ais formed in waste bin12at the periphery of receptacle40to help canter and guide torque tab43into said receptacle40. Moreover, receptacle40is wider than heretofore known to further facilitate vertical entry of torque tab43into said torque tab receptacle40.

As perhaps best understood in connection withFIGS. 3E and 3F, a second embodiment of microswitch actuating tab19is denoted inFIGS. 3E and 3Fby the reference numeral44as a whole. Microswitch actuating tab44has a construction that extends to a higher elevation than the microswitch actuating tabs of the prior art. Moreover, top section44athereof widens from top to bottom and bottom section44bnarrows from top to bottom. Thus, mid-section44cis the widest part of said tab44. A “door closed” signal is generated and sent to activate the printer even if the printer has worn hinges and latches, due to the increased height of tab44. The narrow top edge of tab44facilitates its entry into a narrow opening formed in the bottom edge of the printer door, not shown, and widened middle section44chelps it positively engage said narrow opening while centering the printer door. The novel structure also provides additional protection against breakage of said tab44.

A thicker and taller embodiment of microswitch actuating tab44is depicted inFIG. 2Aand denoted by the reference numeral19. Its increased height allows for even more wear in the hinges and latches and its increased thickness provides enhanced durability and structural strength to center the door.

A number of additional novel features are depicted inFIG. 4Awhich provides an elevational view of the drive side of novel waste bin12. Beginning at the left side of said Figure, it will first be observed that planar wing50is shorter than a conventional planar wing by about one-quarter inch as indicated as at51. This shortening is required because planar wing50is thicker than a conventional planar wing at said leading end. Unlike conventional planar wings, planar wing50has a uniform thickness along its extent. This structure increases the strength of planar wing50and eliminates flexing that causes binding and cocking of the toner cartridge during its installation into a printer. The uniform thickness also makes the novel planar wing less prone to cracking and breaking than the planar wings heretofore known.

The trailing end of planar wing is bifurcated into upper section53aand lower section53b. Said parts cooperate with one another to form a latch member having a function disclosed in connection withFIGS. 12A-F.

Concave depression52helps to lock waste bin12into its functional position in the printer. Specifically, concave depression52extends from about point52ato about point52band receives downward forcing levers that form a part of the printer. Concavity52thus helps to center the force provided by said downward forcing levers.

Wall54has a lower elevation than its prior art counterpart to provide additional clearance for waste bin12when it is pivoted upwardly relative to the printer during removal. This makes the novel toner cartridge easier to remove.

Vent56enhances cooling air flow to the photoconductor drum, not shown.

A plurality of strengthening ribs, collectively denoted58, improve the structural integrity of waste bin12.

Hopper pin mounting aperture60receives a mounting pin62(FIGS. 1A and 1C) mounted to hopper14with zero vertical clearance. Upper spacer61aand lower spacer61breduce the vertical clearance of said mounting aperture60. The hopper pin mounting aperture of the prior art provides vertical clearance because prior art hoppers are pivotally mounted to their associated waste bins. By eliminating the pivotal interconnection between waste bin12and hopper14, various springs are eliminated. Moreover, the zero clearance locks novel hopper14into position relative to novel waste bin12so no shipping strap is required when novel toner cartridge10is shipped.

FIG. 4Bis a side elevational view of the driven side of the toner cartridge. It therefore shows much of the same structure, as indicated by the common reference numerals. One difference is the three photoconductive drum cooling vent holes, collectively denoted56, instead of the single vent hole formed in the drive side of waste bin12.

Another difference is that a structure for preventing problematic “piggy backing” of circuit boards onto a host circuit board may be seen in saidFIG. 4B, said structure not being present on the drive side of waste bin12. This novel structure is denoted101, generally, and is disclosed more fully in connection withFIGS. 10A-C.

FIGS. 4C-Edepict the shipping lock strap mentioned above. Shipping lock strap11aincludes brackets11band11cformed integrally at its opposite ends. Such brackets are secured to opposite ends of a prior art hopper14because the hopper pins of such prior art hopper is free to move about inside its mating aperture. Hence the need for hold-down strap11ain prior art hopper14, such need being eliminated by the absence of vertical clearance between said pin and aperture in the novel structure as aforesaid.

A first embodiment of the novel latching means for interconnecting waste bin12and hopper14to one another in a non-pivotal interconnection appears to some extent inFIGS. 4A-Bbut is best illustrated inFIGS. 5A-Band6A-B.

Hopper wheel horizontal retainer70and hopper wheel vertical lock72are formed integrally with waste bin12and cooperate with one another to engage hopper wheel64(FIGS. 1A and 1C) that is snapped onto hopper axle65near its leading end as best understood in connection withFIG. 1C.

When hopper wheel64is engaged in horizontal retainer70and hopper wheel vertical lock72, its captured position dictates the elevation of the rear of planar wing53cas depicted inFIGS. 1A and 4A. Horizontal retainer70exerts an upward force on hopper wheel64, causing it to make snug contact at a point on the bottom side of level planar wing53c. Such snug contact ensures proper alignment and orientation of cartridge components when the cartridge is installed into and removed from the printer.

The leveling of the planar wing provides for a smoother glide over printer guides during installation of the cartridge into and removal of the cartridge from the printer.

To assemble novel toner cartridge10, waste bin12is held above hopper14as mentioned earlier in connection withFIGS. 1A-Cso that hopper wheel horizontal retainer70and hopper wheel vertical lock72are positioned directly above hopper wheel64. As waste bin12is lowered, hopper wheel64engages upwardly inclined surface70a(FIGS. 5A-B) of horizontal retainer70and causes horizontal retainer70to deflect from itsFIGS. 5A-Bposition of repose. Hopper wheel64rolls over hump70band the resiliency of horizontal retainer70causes it to move back toward its position of repose, thereby capturing hopper wheel64in concavity70c.

When hopper wheel64is causing horizontal retainer70to deflect away from its position of repose as aforesaid, said hopper wheel simultaneously causes hopper wheel vertical lock72to deflect away from itsFIGS. 5A-Bposition of repose as well. When hopper wheel64clears hook72aat the free end of vertical lock72, said vertical lock moves back toward its position of repose, thereby capturing the bottom of hopper wheel64. In this way, hopper wheel64is captured on a trailing side thereof by concavity70cand on its bottom side by flat wall72bof hook72a.

The deflection of hopper wheel64toward cleaner chamber12is limited by contact of the developer roller (not shown) in the hopper and the photoconductor drum, not shown, in the removable toner cartridge universal adapter.

FIG. 5Billustrates hopper wheel horizontal retainer70and hopper wheel vertical lock72from a forward perspective relative to the rear perspective ofFIG. 5A. It should be understood that bothFIGS. 5A and 5Bare taken from inside waste bin12.FIG. 5Bshows more clearly that said parts70and72are separate parts.

It is also best understood fromFIG. 5Bthat neither part70or72is laterally supported by a wall; note opening71formed in sidewall73of waste bin12. It is this lack or lateral support that requires the engagement of hopper torque tab43(FIG. 1C) and hopper torque tab receptacle40.

FIG. 5Cdepicts an improved hopper wheel horizontal retainer70. Arcuate part70chas a greater circumferential extent in this embodiment and thus more fully captures hopper wheel64, thereby eliminating the need for hopper wheel vertical lock72.

Note inFIG. 5Dhow the bottom of hopper wheel64is supported by flat surface64aof hopper wheel vertical lock72.

FIGS. 6A and 6Bdepict hopper wheel horizontal retainer70and hopper wheel vertical lock72that are positioned on the driven side of waste bin12. They perform the same function as their drive side counterparts and engage and capture the hopper wheel associated with the non-drive side of waste bin12.

FIGS. 7A and 7Bdepict an alternative structure for interlocking waste bin12and hopper14. Both Figures are taken from the inside of said waste bin.FIG. 7Adepicts the structure of the driving side andFIG. 7Bdepicts the structure of the driven side.

This alternative structure eliminates hopper wheel horizontal retainer70but it does not eliminate hopper wheel vertical lock72. Guide rail74is integrally formed with a sidewall of the driving side of waste bin12. As waste bin12is lowered toward hopper14, hopper wheel64rollingly engages guide rail74and said hopper wheel continues to roll down said guide rail until it is captured by hook72aof vertical lock72.

In this embodiment, vertical lock72is supported from behind by a waste bin sidewall. Accordingly, hopper torque tab43is eliminated as is hopper torque tab receptacle40. Hopper torque tab43must be cut off from the hopper before the hopper is inserted into the novel removable toner cartridge universal adapter.

Essentially the same structure is provided on the driven side of waste bin12, as depicted inFIG. 7B.

FIGS. 7A-Cdepicts yet another important feature of novel waste bin12. A thirty degree (30°) taper is formed in aperture80formed in a trailing end of a side wall of waste bin12, said aperture being formed in both the driving and driven sides thereof as depicted in saidFIGS. 7A and 7B. As perhaps best understood in connection with the top plan view ofFIG. 7C, trailing wall80aof aperture80is angled at a thirty degree (30°) angle so that aperture80is smaller on the outside surface of the sidewall than it is on the inside surface thereof. When the trailing end of waste bin12is lowered onto hopper14to interconnect said waste bin and hopper together, the flexible and resilient trailing ends of the waste bin sidewalls are slightly diverged from one another so that pins62that extend from opposite ends of hopper14may enter into the tapered aperture80formed in each of said side walls. As mentioned above, springs are used in prior art toner cartridges to urge the hopper forwardly toward cleaner chamber12so that the photoconductive drum of the waste bin will properly contact the developer roller of the hopper.

The untapered prior art aperture thus provides a mounting means for loosely securing the hopper to the waste bin, but such prior art untapered aperture performs no role in biasing the hopper toward the cleaner chamber.

Thus it is understood that the taper of trailing wall80aurges hopper14forwardly, i.e., toward cleaner chamber12. This eliminates the need for the prior art springs that perform such function.

Both hopper wheel horizontal retainer70and hopper wheel vertical lock72are eliminated in the embodiment ofFIGS. 8A and 8Bwhich depict the driving and driven sides of waste bin12, respectively. Hopper wheel axle retainer90is formed on the inside surface of the driving and driven side walls of waste bin12and is adapted to slidingly receive axle65that extends from the hopper ofFIG. 1Cmodified so that hopper wheel64is removed. More particularly, a raised wall forms retainer90that captures and guides said hopper wheel axle. The lowermost end of each retainer90has a forwardly extending bend90aformed therein so that as trailing wall80aurges hopper14in said forward direction, i.e., toward the leading end of waste bin12and thus toward the printer, said hopper wheel axle is pushed into said forward bend90a. This maintains the nip formed by the contact between the photoconductive drum of waste bin12and the developer roller of hopper14.

Note further that hopper wheel axle retainer90formed in the inner surface of the waste bin side wall at the driving side of the waste bin is supported by said side wall and thus there is no need for torque tab43to be formed in hopper14and thus there is no need for hopper torque tab receptacle40.

Perhaps the best harnessing of the forward bias supplied by tapered wall80ais disclosed in the embodiment ofFIGS. 9A and 9B. In this embodiment, both hopper wheel horizontal retainer70and hopper wheel vertical lock72are again eliminated, as is hopper wheel axle retainer90. In this alternative embodiment, the hopper wheel axle retainer is not a raised wall as in the embodiment ofFIGS. 8A and 8Bbut is a straight, horizontally disposed slot92formed in the waste bin side walls on both the driving and the driven sides of waste bin12. Hopper wheel axles65with wheel64removed are aligned with slots92and slidingly introduced thereinto. Hopper mounting pins62,62(FIGS. 1A-C) on opposite ends of hopper14are then inserted into their respective apertures80,80. The respective tapered walls80a,80ashove hopper14forward until the developer roller in the hopper contacts the photoconductive drum in the removable toner cartridge universal adapter.

As in the preceding embodiment, there is no need for torque tab43formed in hopper14and thus there is no need for hopper torque tab receptacle40.

FIG. 10Aprovides an enlarged view of the novel structure101that prevents “piggy backing” of a problematic circuit board over a vertically-mounted host circuit board. There is no “piggy backing” problem associated with horizontally-mounted circuit boards. Flat mounting surface100is recessed with respect to raised flat mounting surface112and said mounting surface100is therefore adapted to receive thereon a circuit board that is smaller than a circuit board supported by raised surface112. Whether small or large, the circuit board is electrically contacted by spring-loaded contacts in the printer. When a “piggy back” circuit board is placed over the host circuit board, the spring-loaded contacts in the printer urge the contacts onto the “piggy back” circuit board with a force that can damage the spring-loaded contacts by over-compressing the contacts in the printer beyond their normal limits due to the double thickness of the two circuit boards.

A pair of arcuate blocking members is therefore provided. Upper arcuate member102extends from a point just above raised mounting surface112to a lower surface of planar wing50. Lower arcuate member104extends from a point just below said raised mounting surface112to a preselected point at a still further lower elevation. Both arcuate members are preferably formed of a high impact plastic. Unauthorized circuit boards are substantially larger than the authorized board, so the presence of arcuate blocking members102,104obstructs the placing of a “piggy back” circuit board over the host circuit board.

Wall103to which arcuate members102and104are mounted is called a skeg wall in the industry. More particularly, it is called the driven side skeg wall because it is positioned on the driven side of toner cartridge10. Directional arrows103aat the lower right corner ofFIG. 10Aindicate that the lower edge of skeg wall103has been cut so that it is flat. Specifically, about four millimeters (4 mm) have been shaved from the bottom edge of a skeg wall of the prior art. This enables the mated hopper and waste bin to sit in a stable position, i.e., without wobbling, on a flat surface external to a printer, i.e., when said mated waste bin and hopper are not positioned in a printer-receiving cavity. The skeg wall of prior art toner cartridges introduces instability and said prior art toner cartridges therefore wobble when placed on a flat surface external to a printer.

Plastic brace106is bent downwardly in an arc as shown to provide additional support to upper arcuate member102so that said arcuate member102cannot be displaced rearwardly to make room for a “piggy back” circuit board.

FIG. 10Bis a perspective view of recessed surface100and raised surface112.FIG. 10Cprovides an enlarged view of embodiment ofFIG. 10B. Recess100is adapted to receive a small circuit board, not shown in this figure, and raised surface112receives a larger circuit board, not shown in this figure.

FIG. 11is a rear perspective view of waste bin12. Downward forcing wheel55athat forms a part of downward forcing lever assembly55is depicted in rolling engagement with concavity52.

FIGS. 12A-Fprovide an animation depicting the insertion of a planar wing50into receiving cavity57of a printer. The trailing end of planar wing50is bifurcated into upper section53aand lower section53band performs a latch function when lower section53bis fully received within catch cavity57aat the trailing end of receiving cavity57. The small size of lower section53breduces its contact area with receiving cavity57, thereby making it easy to insert and remove toner cartridge10into and from the printer, respectively.

FIG. 13is a perspective view depicting an embodiment of planar wing50where said planar wing is discontinuous. The leading part is denoted50aand the trailing part thereof is denoted50b.

FIG. 14is a perspective view depicting still another alternative embodiment where continuous planar wing50and discontinuous planar wings50aand50bare both replaced by a plurality of wheel assemblies. Wheels59a,59b, and59care mounted on axles63a,63b, and63c, respectively. The axles are formed of a flexible and resilient material and are diametrically split as at63d,63e, and63f, respectively. Thus, they are squeezed when the wheels are placed thereon so that when said axles are released from said squeeze, the axles expand and hold the wheels in place. Flat plate66and locating pin68collectively perform the function of parts53a,53bin the above-disclosed embodiments of planar wing50.

FIGS. 15A-Fdepict how the assembly ofFIG. 14is inserted into printer receiving cavity57.

These wheels provide support at key positions during installation, engagement and removal of the cartridge from the printer.

FIGS. 16A and 16Bdepict an embodiment of the novel toner cartridge where two independently-generated electrical signals are used to activate a printer. Both signals are fed to a circuit board that activates the printer. One of the signals identifies a family of printers to which a printer belongs, and the other signal identifies the brand name of the printer within that family.

Rotatably mounted dial120, also known as a brand selector switch, is mounted on circuit board110a. It has a plurality of discrete settings, collectively denoted122. Dial120enables a user to visually identify a printer by its brand name and to set dial120to a setting122that tells circuit board110what that brand name is.

A conductive ribbon124interconnects circuit board110and a microswitch having an actuator that is actuated when contacted by a protuberance formed in a printer. Thus, the protuberance depresses the actuator and the microswitch sends a signal that indicates the printer family through ribbon124to circuit board110that enables the operation of the cartridge in the printer. Selector switch120ais also in electrical communication with circuit board110. In this way, the signal carried to the circuit board by ribbon124tells circuit board110what family the printer belongs to and the user, by manipulating selector switch120a, tells the circuit board the brand name of the printer within the family. So that the correct communication occurs, the brand and family information are then sent to an electronic device, not shown, that would be mounted on circuit board110. This semi-automatic switching system allows a cartridge to determine within which particular printer it has been installed.

There are numerous possible positions for the microswitch and there may be any number and types of microswitches at differing positions. Moreover, the microswitch may be provided in many different forms. For example, depressible keypads of the type commonly used in microwave ovens, which may also be referred to as pressure-sensitive flexible printed circuit board switches, may be used in lieu of the switch depicted in said Figs. Moreover, the microswitch may take the form of an optical microswitch. All known microswitches are within the scope of this invention.

In the example ofFIGS. 16A and 16B, microswitch126is positioned in a recess126aat the bight of leading end recess16bso that microswitch actuator128extends into said leading end recess. Accordingly, a force applied in the direction of directional arrow130activates actuator128. Such force is applied by a protrusion or protuberance formed in the printer into which the novel toner cartridge is inserted. Depression of actuator128by said protuberance activates microswitch126and said microswitch sends a signal to circuit board110.

Second switch actuator132is positioned in one of the outboard recesses. It operates in the same way as actuator128, i.e., a force exerted in the direction of directional arrow134causes actuator132to close a switch and send a signal to circuit board110.

The invention is not limited to this particular arrangement of microswitches because printer manufacturers may in the future change their respective printer structures. However, the principle of universality disclosed herein enables the designer of toner cartridges to change the switch positions or to add more switches as needed.

However, the two switch/switch actuator arrangement ofFIGS. 16A-Cis very powerful in that it enables the identification of all of the printer families mentioned above. Thus, it enables the identification of all printers in the 520, 620, and 630 family of printers. It also identifies all printers in the Se/T family of printers as well as printers having no circuit boards. It does not identify the brand name of a printer within a family, said function being performed by a user as disclosed above.

More particularly, a toner cartridge-receiving printer cavity having a front-mounted, vertically disposed circuit board port and first and second protuberances25a,25bformed therein at opposite ends thereof as depicted inFIG. 16Eis identified by contact with second switch actuator132which is positioned at the outboard edge of the novel universal waste bin as aforesaid. The switch associated with said actuator, when closed, sends a signal to the printer controller electronics, or universal printer chip, that activates a family of printers having said arrangement of first and second protuberances. In this example, the signal would activate any member of the 620 family of printers.

More specifically, the signal will activate all of the following printers: Optra SE3455, Lexmark T620*, Lexmark T622*, IBM Infoprint 1130*, IBM Infoprint 1140*, Nashuatec P6015, Nashuatec P6230*, Nashuatec P6240*, Source Technologies ST915, Source Technologies ST920, Source Technologies ST925, Source Technologies ST935*, Source Technologies ST9130*, Source Technologies ST9140*, Source Technologies ST1130*, Source Technologies 1140*, Unisys UDS15, Unisys UDS20, Unisys UDS25, Unisys UDS35, Unisys UDS134*, Unisys UDS136*, Toshiba E-Studio 30P* and Toshiba E-Studio 40P*. All model numbers with an asterisk (*) use front-mounted, vertically-disposed circuit board contacts. The model numbers without an asterisk use horizontally-mounted circuit board contacts.

A toner cartridge-receiving printer cavity having a front-mounted, vertically disposed circuit board port and a left of center protuberance25dformed therein as depicted inFIG. 16Fis identified by absence of contact with actuator switch128positioned in the center recess of the waste bin and by absence of contact with actuator switch132positioned in a recess formed in the outboard edge of the waste bin. The lack of communication from either of such switches indicates that the printer is a member of the 630 family of printers.

The toner cartridge-receiving cavity ofFIG. 16Fhas utility with the following printers: Dell W5300n*, Lexmark T632*, Lexmark T634*, IBM Infoprint 1352*, IBM Infoprint 1372*, Source Technologies ST9340*, Source Technologies 1352*, Toshiba e-Studio 400P*, Unisys UDS 142*, and Unisys 144*. The asterisk (*) indicates that the printer uses front contacts, i.e., contacts that electrically engage vertically-mounted circuit boards.

A toner cartridge-receiving printer cavity having a front-mounted, vertically disposed circuit board port and a centered protuberance25eformed therein as depicted inFIG. 16Gis identified by contact with actuator switch128positioned in the center recess of the waste bin. Switch126, when closed, sends a signal to the printer controller electronics, or universal printer chip, that activates any member of the 520 family of printers. Printers in this family would not activate second switch actuator132. Thus, the 520 family is identified by the presence of a signal from first switch126and an absence of a signal from the switch actuated by actuator132.

The toner cartridge-receiving cavity ofFIG. 16Ghas utility with the following printer models: Lexmark T520*, Lexmark T522*, Nashuatec P6220*, Nashuatec P6225*, IBM Infoprint 1120*, IBM Infoprint 1125*, Source Technologies ST9120*, Source Technologies ST9125*, Source Technologies 1120*, Source Technologies 1125*, Unisys UDS 130*, Unisys UDS 132*, Toshiba E-Studio 20P*, and Toshiba E-Studio 25P*, all of which use front contacts as indicated by the asterisk associated with each model.

A toner cartridge-receiving printer cavity having a front-mounted, vertically disposed circuit board port and a right of center protuberance25fformed therein as depicted inFIG. 16His identified by absence of contact with actuator switch128positioned in the center recess of the waste bin and by absence of contact with actuator switch132positioned in a recess formed in the outboard edge of the waste bin. The lack of communication from either of such switches indicates that the printer is also a member of the 630 family of printers.

The toner cartridge-receiving cavity ofFIG. 16Fhas utility with the following printer models, all of which use front contacts as indicated by the asterisk associated with each model: Lexmark T630*, IBM 1332*, Dell M5200N*, Source Technologies 9335*, and Source Technologies 1332*.

A printer having a top-mounted, generally horizontally disposed circuit board takes precedence over any switch signals that might otherwise be communicated to denote a family of printers that singularly employ such horizontal circuit board mounting. In other words, signals from a switch or switches actuated by the presence of a particular arrangement of protuberances of the type that might be found in printers having front-mounted, vertical circuit boards are ignored if a top-mounted, generally horizontally disposed circuit board is detected. Any printer in the Se/T family of printers would thus be recognized.

The novel universal waste bin of this invention is also compatible with printers having no circuit board ports, such as depicted inFIG. 16I. Such printers do not electrically communicate with their associated toner cartridges. A printer of such type requires no communication from its associated toner cartridge so there is no need for any switch to be actuated. Thus, signals that may be sent upon depression of switch actuators by a toner cartridge are ignored when a printer of this type is detected.

Printers having no circuit board ports include the Optra S, Optra S 1250, Optra S 1255, Optra S 1620, Optra S 1625, Optra S 1650, Optra S1855, Optra S 2420, Optra S 2455, Unisys UDS 9712, Unisys UDS 9716, and2 Unisys UDS 9718.

As mentioned above, it is not enough to identify a printer just by the family to which it belongs. The 520 family includes printers sold under the brand names Lexmark®, Source Technologies®, Toshiba®, and IBM®. The 620 family includes printers sold under the same brand names as the 520 family, but the model numbers of the 620 family printers are different from the model numbers of the 520 family. Similarly, the 630 family includes the same printer brands as the 520 and 620 families, and with Dell® printers as well, but again with model numbers different from the model numbers of the 520 and 620 families.

Thus it is necessary for a user to identify the brand name of the printer after the family has been automatically identified in the manner disclosed above. The user need not know which family the printer belongs to because that is determined by the structure just disclosed. However, when the user identifies the brand name of the printer in a particular family, the electronic circuitry then knows both the family and the printer within that family and the printer may then be activated with the correct electrical handshake and other required data.

The printer selector switch120depicted inFIGS. 16A and 16Bis of the rotary type. The printer selector switch120adepicted inFIG. 16Cis of the slide type, as is the switch depicted inFIGS. 17A and 17C. The invention is not limited to these two (2) types of selector switches. More particularly, in addition to rotary and slide-type selector switches, jumpers, button array, and other selector switches are within the scope of this invention.

FIGS. 17A and 17Cdepict the use of the above-mentioned pressure-sensitive flexible printed circuit board switches. They are denoted128aand132ato suggest that they are one of many substitute switches and switch actuators that may be used in lieu of actuators128and132.FIG. 17Aalso better depicts ribbon cable124. It should be understood, however, that ribbon cable124may be replaced by any equivalent conductor, including optical fibers, conventional wires, flexible circuit boards, and the like.

As perhaps best understood in connection withFIG. 17B, a channel124ais formed in the novel toner cartridge to accommodate ribbon cable124or its equivalent. The recessed mounting provided by the channel prevents damage to conductor124during insertion of the toner cartridge into the printer.

An opening134(FIGS. 17C and 17D) is formed in a vertical wall of waste bin12between the outboard edge of toner cartridge10and an outboard edge of the sculpted leading end of said waste bin. The opening is structurally reinforced about its perimeter as denoted by the reference numeral135. Opening134enables ribbon cable124, and its equivalents, to follow a path of travel from vertical circuit board110to switch actuators126and132and their equivalents where at least part of that path of travel is internal to toner cartridge10.

Note inFIG. 16Bthat in the absence of opening134, opening138must be formed in wall140to enable said ribbon cable to complete said path of travel.

Connection pads111a,113aare mounted on horizontally-mounted circuit board110aand are adapted to make electrical contact with upper door-mounted electrical contacts that are provided on printers of the Se/T family.

Connection pads111,113are mounted on vertically-mounted circuit board110and are adapted to make electrical contact with electrical contacts of the type provided on printers of the 520, 620, and 630 families.

Label115is mounted in recessed area117and provides instructions to the user. An example of typical instructions is provided inFIG. 17E. The invention is not limited to four brands of printers as indicated in the illustrative label of saidFIG. 17E.

FIG. 17Ealso provides a view that clearly depicts connector123that provides electrical communication between a first end of ribbon cable124and horizontal circuit board110a. More particularly, terminal connector123ais mounted to the end of ribbon cable124and said terminal connector123amakes electrical contact with said connector123.

A similar construction is employed at a second, opposite end of ribbon cable124as depicted inFIG. 17Fwhere said ribbon cable is in electrical communication with vertically-mounted circuit board110. Terminal connector125ais mounted to the second end of ribbon cable124and said terminal connector125amakes electrical contact with receiving connector125that is mounted to said circuit board110.

As depicted inFIG. 17F, a similar connection is provided between ribbon cable124aand vertical circuit board110. Specifically, terminal connector127ais mounted to a first end of ribbon cable124aand said terminal connector127amakes electrical contact with receiving connector127that is mounted to circuit board110.

“L”-shaped circuit board110a, depicted inFIG. 17G, has utility because it provides a mount for vertically-disposed receiving connector129to which vertically-disposed terminal connector125amay be secured in the absence of any bends in ribbon cable124. Note in the embodiment ofFIG. 17Fthat connectors125and125aare horizontally and vertically disposed, respectively.

FIGS. 18A and 18Bdepict a substantially horizontal slot142having a flat, horizontally disposed upper wall142aand a flat, horizontally disposed lower wall142b. Slot142is formed in an interior sidewall of the driven side of the waste bin between protrusion16aand hopper wheel vertical lock70.

As depicted inFIG. 18B, a novel upper shutter144is a bi-fold door having half parts144a,144b. Trailing half part144bis hingedly connected as at146a,146bto the top wall of toner cartridge12and leading half part144ais similarly connected to said toner cartridge top wall. The two half parts meet at folding line148. Specifically, the trailing end of leading half144ais hingedly connected to the leading end of trailing half144b. Hinge150is in alignment with folding line148and extends from the driven side of shutter144into slot142. Hinge150is therefore constrained to move within slot142as shutter144is opened and closed. More particularly, hinge150travels within slot142in a trailing-to-leading direction when shutter144is opened, and said hinge150travels within slot142in a leading-to-trailing direction when shutter142is closed. The driving side of shutter144is unconstrained.

In all of these exemplary constructions, it should be understood that the specific terminal connectors and receiving connectors disclosed herein may take many forms that are well-known in the electrical arts and all of such alternative forms are within the scope of this invention. For example, solder may be used to form the needed electrical connections.

Now that the invention has been described,