Method of remanufacturing a toner cartridge

A method of remanufacturing a toner cartridge includes installing a modified end cap in which a portion of a drive assembly for an internal toner seal removal mechanism has been disabled. With the modified end cap installed, the toner cartridge may be post tested without removing the internal toner seal. When the post test is complete the modified end cap is removed and a non-modified end cap with a functional drive assembly is installed in its place.

BACKGROUND

The present disclosure relates to consumable cartridges used in image forming apparatuses, and more specifically to a remanufactured cartridge that has been modified to permit testing of the cartridge after the remanufacturing without disturbing a toner seal configuration that reduces leakage of toner from the cartridge during shipping.

Imaging cartridges, and particularly toner cartridges, are frequently provided with toner seals that cover a toner opening provided in the toner hopper through which toner is dispensed during operation of the cartridge. These seals are removable just prior to the toner cartridge being used for a printing operation either manually by a user or by a mechanism included in the toner cartridge or the image forming apparatus into which it is installed. The primary function of the seal is to prevent toner from leaking out of the toner opening of the cartridge during transportation and shipping of the toner cartridge.

Toner cartridge remanufacturers often perform a post test of the remanufactured cartridges after the cartridges have gone through the remanufacturing process but before they are packaged for sale to the end user. The post test is intended to reveal any issues that may have arisen during the remanufacturing process. If the post test reveals a printing defect the cartridge can be removed from the production line and the issue investigated. Although the specific technique may vary depending on the configuration of a specific cartridge, to conduct a post test remanufacturers will often insert a relatively small test charge of toner into the space between the developer roller and the “clean” side of the toner seal. In a typical post test the toner seal remains intact and print tests are conducted using the test charge of toner which makes its way through the cartridge in the same manner as toner from the hopper would if the toner seal was not present. When the post test is complete, remaining test charge toner may be vacuumed or blown from the cartridge before packaging.

Toner cartridges such as those disclosed in U.S. Pat. No. 9,164,430 (the '430 patent, the entire contents of which are hereby incorporated by reference herein) include a rotatable member within the toner hopper that removes an internal toner seal. Before the cartridge is inserted into a printer, the internal toner seal prevents toner from leaking out of a toner accommodating area. When the cartridge is inserted into the printer, driving rotatable force from the printer is transmitted to the cartridge through a drive mechanism. The drive mechanism operates a gear assembly in the cartridge which in turn rotates the rotatable member. When the rotatable member rotates it pulls the internal toner seal away from the toner opening, thereby allowing toner to flow through the toner opening toward the developer roller. Because the internal toner seal is automatically removed when the cartridge is inserted into the printer, post testing a cartridge that is remanufactured back to its original configuration would cause the internal toner seal to be removed, which may result in undesirable leaking of toner from the cartridge during packaging and shipment.

SUMMARY

In some aspects, a method of modifying a toner cartridge component to permit a post test of the toner cartridge without removing an internal toner seal is provided and includes uncovering a drive mechanism for driving a toner seal removal mechanism, disabling at least a portion of the drive mechanism, and recovering the drive mechanism while the at least a portion of the drive mechanism is disabled.

Disabling at least a portion of the drive mechanism may include removing at least one gear of the drive mechanism. Uncovering the drive mechanism may include removing a portion of the toner cartridge that at least partially covers the drive mechanism. Removing a portion of the toner cartridge may include removing at least the portion of the drive mechanism. Removing the portion of the toner cartridge may include removing a first end cap, and recovering the drive mechanism may include installing a second end cap. Recovering the drive mechanism may include reinstalling a portion of the toner cartridge that at least partially covers the drive mechanism. The method may also include separating a hopper section of the cartridge from a waste section of the cartridge before uncovering the drive mechanism. The method may also include reconnecting the hopper section of the cartridge to the waste section of the cartridge after recovering the drive mechanism.

In other aspects, a method of remanufacturing a toner cartridge is provided and includes obtaining a used toner cartridge configured for use with an internal toner seal that is automatically removed upon installation of the toner cartridge in a printer. The method also includes refilling a hopper section of the toner cartridge and installing the internal toner seal, uncovering a drive mechanism for operating a toner seal removal mechanism, disabling the drive mechanism to prevent operation of the toner seal removal mechanism, recovering the drive mechanism while the drive mechanism is disabled, installing the toner cartridge with the disabled drive mechanism into a printer to perform a post test, removing the toner cartridge from the printer after the post test, again uncovering the drive mechanism after removing the toner cartridge from the printer after the post test, and re-enabling the drive mechanism to permit operation of the toner seal removal mechanism.

Disabling the drive mechanism may include removing at least one gear from the drive mechanism. Uncovering the drive mechanism may include removing a portion of the toner cartridge. Removing the portion of the toner cartridge may include removing a portion of the drive mechanism. Uncovering the drive mechanism may include removing an end cap of the toner cartridge. Recovering the drive mechanism may include installing a portion of the toner cartridge. Re-enabling the drive mechanism may include replacing at least one gear of the drive mechanism.

In still other aspects, a method of remanufacturing a toner cartridge is provided and includes obtaining a used toner cartridge configured for use with an internal toner seal that is automatically removed upon installation of the toner cartridge in a printer, refilling a hopper section of the toner cartridge and installing the internal toner seal, removing an end cap of the toner cartridge, the end cap including a drive mechanism for operating a toner seal removal mechanism, creating a modified end cap to disable the drive mechanism, installing the modified end cap onto the toner cartridge, installing the toner cartridge with the modified end cap into a printer to perform a post test, removing the toner cartridge from the printer after the post test, removing the modified end cap, and installing a non-modified end cap with a functional drive mechanism to permit operation of the toner seal removal mechanism upon a subsequent insertion of the toner cartridge into a printer.

Creating the modified end cap may include removing at least one gear. Installing the non-modified end cap may include reinstalling the end cap that was previously removed.

In still other aspects, a method of remanufacturing a plurality of toner cartridges is provided and includes obtaining a plurality of used toner cartridges, each toner cartridge configured for use with an internal toner seal that is automatically removed upon installation of the toner cartridge in a printer, and each toner cartridge including an end cap including a drive mechanism for operating a toner seal removal mechanism, harvesting a plurality of the end caps from some of the plurality of used toner cartridges, modifying the harvested plurality of end caps to disable the drive mechanism in each end cap, installing one of the modified plurality of end caps on each of the plurality of used toner cartridges during a remanufacturing process, post testing the toner cartridges that have received one of the modified plurality of end caps, removing the modified end cap from each post tested toner cartridge, and installing a non-modified end cap with a functional drive mechanism on each post tested toner cartridge.

Modifying the harvested plurality of end caps may include removing at least one gear from the drive mechanism in each end cap. The method may also include reusing the removed modified end caps.

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.

DETAILED DESCRIPTION

FIG. 1illustrates a toner cartridge2upon which the remanufacturing methods described herein may be used. The illustrated toner cartridge is an HP CF287A type toner cartridge, but those skilled in the art will appreciate that the methods described herein may be used in connection with other types and brands of toner cartridges. The toner cartridge2includes a waste section4rotatably supporting an OPC drum8. A hopper section10, which holds toner for printing, is coupled to the waste section4. In the illustrated cartridge2the waste section4and the hopper section10are pivotably coupled to one another by pins12(only one pin shown inFIG. 1), and can be separated from one another by removing the pins12.

Referring also toFIG. 2, the hopper section10includes a main body14to which the other components are secured. For example, an end cap18is secured to one end of the main body14and rotatably supports a mag roller gear22, which in turn rotatably supports one end of a mag roller26. The mag roller26, which may be referred to as a developer roller in other applications, rotates during printing operations and supplies toner to the OPC drum8in a known manner. Within the illustrated hopper section10, there is a toner window located behind the mag roller26and therefore not visible inFIG. 2. As described, for example, in the '430 patent, the toner window defines a boundary between a toner storage chamber within the hopper section and a toner transfer chamber within the hopper section. Before the cartridge2is inserted into a printer a toner seal covers the toner window and prevents the movement of toner from the toner storage chamber to the toner transfer chamber to minimize leakage of toner from the cartridge2during packaging and shipment. When the cartridge2is inserted into a printer for the first time, a toner seal removal mechanism within the hopper section10operates to pull the seal away from the toner window, thereby allowing toner to move from the toner storage chamber to the toner transfer chamber where it can be transferred to the mag roller26and ultimately to the OPC drum8during a printing operation. In the exemplary toner cartridge2, the toner seal removal mechanism includes an axle rotatably mounted within the hopper section10and extending substantially parallel to the mag roller26. One end of the toner seal is coupled to the axle and the other end is coupled to the toner window such that when the axle rotates the toner seal is pulled away from the toner window. Once the toner seal is removed it functions as an agitator within the hopper section10to promote the movement of toner from the toner storage chamber to the toner transfer chamber.

When remanufacturing the toner cartridge2, it may be desirable to provide the end user with a use experience that is as close to the original OEM configuration as possible. For this reason it may be desirable to install or reuse an internal seal that functions in the same way as the seal described above, e.g., an internal seal that is automatically removed upon insertion of the cartridge2into a printer. However, because it is also desirable to post test remanufactured cartridges, steps may be taken to prevent the internal seal from being removed during the post test to preserve the leak-reducing function of the internal seal.

Referring also toFIGS. 3-6, the end cap18of the cartridge2may be modified to prevent removal of the internal seal during a post test.FIGS. 3 and 4illustrate the end cap18in an unmodified configuration. The end cap18includes an outer wall34and sidewalls38. The outer wall34and sidewalls38cooperate to define a cavity42that houses a drive mechanism46for driving the toner seal removal mechanism. The illustrated drive mechanism46includes the mag roller gear22, an intermediate gear50driven by the mag roller gear22, and a drive gear54driven by the mag roller gear22via the intermediate gear (seeFIG. 5) and operable to drive the toner seal removal mechanism within the hopper section10. The drive mechanism46also includes a retainer58that partially supports the mag roller gear22and that overlies a portion of the intermediate gear50to retain and locate the intermediate gear50and the drive gear54within the cavity42.

During normal operation driving rotatable force provided by the printer is transmitted to the mag roller26. Rotation of the mag roller26causes rotation of the mag roller gear22, which rotates the intermediate gear50, which in turn rotates the drive gear54. The drive gear54rotates a driven gear (not shown) associated with the toner seal removal mechanism. Rotation of the toner seal removal mechanism removes the toner seal, as described above.

Modification of the end cap18to prevent removal of the internal seal during a post test may include at least partially disabling the drive mechanism46. One way of at least partially disabling the drive mechanism46includes removing at least one of the intermediate gear50and the drive gear54. To remove one or both of these gears, the retainer58may be removed, as shown inFIG. 5, which allows the intermediate gear50to be removed from its axle62. Once the intermediate gear50is removed, the drive gear54may also be removed from its axle66and the retainer58may be reinstalled on its mounting posts70(FIG. 6). By removing the intermediate gear50and/or the drive gear54from the cavity42, the mag roller gear22is decoupled from the toner seal removal mechanism provided within the toner hopper10. Thus, with the modified end cap18installed on the cartridge2, when driving rotational force from the printer causes rotation of the mag roller26and mag roller gear22upon installation of the cartridge2into a printer, rotation of the mag roller gear22is not transmitted to the toner seal removal mechanism and the toner seal remains in place. In this way, by installing the modified end cap18onto the toner cartridge2during a remanufacturing operation, a post test can be performed without disturbing the toner seal.

Once the toner cartridge2has been remanufactured and a post test has been completed, the modified end cap18may be removed from the toner cartridge2and a non-modified end cap having a fully functional drive mechanism46(e.g., a drive mechanism that includes both the intermediate gear50and the drive gear54) may be installed in its place. The remanufactured toner cartridge2with the non-modified end cap18may then be packaged and shipped for sale to an end user. Upon installation of the remanufactured cartridge2with the non-modified end cap18into a printer, the drive mechanism46will function normally to transmit driving rotational force to the toner seal removal mechanism such that the toner seal is removed and normal printing can commence.

When the modified end cap18is removed from the cartridge2after the post test, the modified end cap18may be returned to an earlier position on the assembly line to be used again in the manufacturing of another toner cartridge2. In this way, a remanufacturer may harvest a plurality of end caps from used toner cartridges and modify the harvested plurality of end caps for repeated use in its remanufacturing operations. These modified end caps18may be specially marked or labeled to clearly distinguish the modified end caps18from the unmodified end caps18.

In view of the above, methods for remanufacturing toner cartridges may be provided. For example, and with reference toFIG. 7, a method of modifying a toner cartridge component to permit a post test of the toner cartridge without removing an internal toner seal may be provided. The method may include removing a portion (e.g., the end cap18) of the toner cartridge that includes a drive mechanism46for driving a toner seal removal mechanism as at100to uncover the drive mechanism46. The method may also include, disabling at least a portion of the drive mechanism46as at104, and installing or reinstalling (as the case may be) the portion of the toner cartridge to recover the drive mechanism46while at least a portion of the drive mechanism is disabled as at108. Disabling at least a portion of the drive mechanism may include removing at least one gear (e.g., intermediate gear50or drive gear54) of the drive mechanism. Removing the portion of the toner cartridge that includes the drive mechanism may include removing the portion of the toner cartridge and the drive mechanism as a single piece. Reinstalling the portion of the toner cartridge may include reinstalling the portion of the toner cartridge and the drive mechanism as a single piece. The method may also include separating a hopper section10of the cartridge2from a waste section4of the cartridge2, as described above, before removing the portion of the toner cartridge. The method may also further include reconnecting the hopper section10of the cartridge2to the waste section4of the cartridge after reinstalling the portion of the toner cartridge.

With reference toFIG. 8, another exemplary method of remanufacturing a toner cartridge includes obtaining a used toner cartridge configured for use with an internal toner seal that is automatically removed upon installation of the toner cartridge in a printer as at112, refilling a hopper section of the toner cartridge with toner as at116, and installing the internal toner seal as at120. The method may also include removing a portion of the toner cartridge (e.g., the end cap18) to uncover a drive mechanism46for operating a toner seal removal mechanism as at124. At least a portion of the drive mechanism may then be disabled as at128, and the portion of the toner cartridge may be reinstalled to recover the drive mechanism46while the drive mechanism46is disabled as at132. Recovering the drive mechanism in this context may include the situation where the drive mechanism46is part of the end cap18such that installing the end cap18on the cartridge captures the drive mechanism between the end cap18and the toner hopper10. The method may also include installing the toner cartridge with the disabled drive mechanism into a printer to perform a post test as at136, during which time the toner seal is not removed, and removing the toner cartridge from the printer after the post test. With the post test complete, the portion of the toner cartridge (e.g., the end cap18) may be removed to uncover the disabled drive mechanism as at140, and the drive mechanism may be re-enabled to permit operation of the toner seal removal mechanism as at144. In this context, re-enabling the drive mechanism may include installing an end cap18with a functional drive mechanism in place of the modified end cap18with the non-functional drive mechanism.

In this example, the drive mechanism for operating the toner seal removal mechanism may include a plurality of gears, and disabling the drive mechanism may include removing at least one gear from the drive mechanism. As noted, the drive mechanism for operating the toner seal removal mechanism may be mounted to the end cap, and disabling the drive mechanism may include removing at least one gear from the end cap.

With reference toFIG. 9, another exemplary method of remanufacturing a toner cartridge includes obtaining a used toner cartridge configured for use with an internal toner seal that is automatically removed upon installation of the toner cartridge in a printer as at148. A hopper section of the toner cartridge may be refilled as at152, and the original internal toner seal or a replacement internal toner seal may be installed over a toner window inside the hopper section as at156. An end cap18of the toner cartridge including a drive mechanism for operating a toner seal removal mechanism may be removed as at160. A modified end cap with a disabled drive mechanism46, which may be the original end cap or a different end cap, may then be created and installed onto the toner cartridge as at164, and the toner cartridge with the modified end cap may be installed into a printer to perform a post test as at168. Because the drive mechanism46is disabled, the internal toner seal will not be removed during the post test. After the post test the toner cartridge is removed from the printer and the modified end cap is removed from the cartridge as at172. A non-modified end cap with a functional drive mechanism is then installed onto the cartridge as at176to permit operation of the toner seal removal mechanism upon a subsequent insertion of the toner cartridge into a printer.

With reference toFIG. 10, another exemplary method includes remanufacturing a plurality of toner cartridges. This method includes obtaining a plurality of used toner cartridges as at180, where each toner cartridge is configured for use with an internal toner seal that is automatically removed upon installation of the toner cartridge in a printer, and further where each toner cartridge includes an end cap18including a drive mechanism46for operating a toner seal removal mechanism. A plurality of end caps may be harvested from some of the used toner cartridges as at184, and the harvested end caps may be modified to disable the drive mechanism46in each end cap as at188, for example by removing at least one gear of the drive mechanism46. The modified end caps are installed onto the toner cartridges during a remanufacturing process as at192. More specifically, one modified end cap is installed on each toner cartridge that goes through the remanufacturing process. The toner cartridges including the modified end caps that have gone through the remanufacturing process are then post tested as at196. The modified end caps are removed from the post tested toner cartridges as at200, and non-modified end caps with functional drive mechanisms are installed onto the post tested toner cartridges as at204. The modified end caps may then be reused on other toner cartridges that are undergoing the remanufacturing process as at208.

It should be appreciated that the exemplary description provided above refers to one specific style of toner cartridge, but that the teachings and concepts set forth may be applied to a variety of toner cartridges having different forms of construction. For example, other toner cartridges may have a different arrangement of end caps, gears, and the like such that more or fewer components are modified or removed to prevent the toner seal from being removed during a post test. In addition, the method steps described above are not necessarily required to be performed in the order in which they are described, and not all method steps will be necessary for all types of toner cartridges.

Accordingly, the scope of the invention shall be defined by the following claims and the foregoing exemplary descriptions should not be regarded as limiting.