Abstract:
A method of removing a drum from a printer toner cartridge, the drum comprising a cylindrical body, the drum further comprising a pair of drum gears attached to each end of the drum, each drum gear being configured to attach the drum to the printer, at least one drum gear comprising a cylindrical body, the cylindrical body defining a hollow drum gear interior, at least one drum gear further comprising a drum gear wall that is positioned perpendicular to the cylindrical body and configured to cover the hollow drum gear interior, the method comprising creating a hole through the drum gear wall and inserting a cutting device through the hollow drum gear interior.

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
       [0001]    None 
       FIELD OF INVENTION 
       [0002]    The present invention relates to electrophotography, particularly methods and apparatus for remanufacturing toner cartridges. 
       BACKGROUND 
       [0003]    Used printer cartridges of fax machines, copiers, inkjet printers, and laser printers are often remanufactured. Generally, printers embed toner on paper by relying on electrical charges occurring within the printer cartridges. Printer cartridges typically include a toner hopper, a primary charge roller, and a drum. The toner is typically stored in the toner hopper and carries a negative charge. The drum is typically given a charge by a primary charge roller or PCR. The charge of the drum is typically more positive than the charge of the toner, and thus the drum is able to attract the toner. Once the drum is given a charge by the PCR and a print pattern is set, the drum gets coated with toner. The drum that is coated with toner then rolls over a sheet of paper, which is usually given a negative charge by the PCR. The charge of the paper is less negative than the charge of the toner, and thus the paper attracts the toner. The toner is embedded on the paper according to the print pattern. 
         [0004]    The drum is usually one of the components that wears out from usage and gets replaced during remanufacturing. In some cartridges, such as those manufactured by Hewlett Packard company having model numbers HP 1600, HP 2600, and HP 2605, the drums are attached to the cartridges in a manner that makes the drums difficult to remove from the cartridges and may require breaking the cartridges. It is desirable to be able to detach the drums from the cartridges without having to break the parts of the cartridges. This helps preserve the appearance of the cartridges and minimizes remanufacturing steps. Methods and apparatus for efficiently and quickly detaching the drums from the cartridges are desired and are addressed by the present invention. 
       BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE PRESENT INVENTION 
       [0005]    The present invention includes a method of removing a drum from a printer toner cartridge, the drum comprising a cylindrical body, the drum further comprising a pair of drum gears attached to each end of the drum, each gear being configured to attach the drum to the printer, at least one gear comprising a cylindrical body, the cylindrical body defining a hollow gear interior, at least one gear further comprising a gear wall that is positioned perpendicular to the cylindrical body and configured to cover the hollow gear interior, the method comprising creating a hole through the gear wall and inserting a cutting device through the hollow gear interior. 
         [0006]    The present invention also comprises a cutting device for use in detaching a drum from a printer cartridge, the cutting device comprising a shaft; a recess defined by the shaft; a cutter arm moveably attached to the shaft; a pointed edge integral with the cutter arm, the pointed edge being moveable in and out of the recess; and an actuator attached to the cutter arm, the actuator being configured to move the cutter arm and cause the pointed edge to move in and out of the recess, wherein when the pointed edge is out of the recess, the pointed edge is configured to cut the drum free from the printer cartridge. 
         [0007]    The above description sets forth, rather broadly, a summary of embodiments of the present invention so that the detailed description that follows may be better understood and contributions of the present invention to the art may be better appreciated. Some of the embodiments of the present invention may not include all of the features or characteristics listed in the above summary. There may be, of course, other features of the invention that will be described below and may form the subject matter of claims. In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and to the arrangement of the components set forth in the following description or as illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is substantially a perspective view of an embodiment of a cutting tool of the present invention. 
           [0009]      FIG. 2  is substantially a cross-sectional view of the cutting tool shown in  FIG. 1 . 
           [0010]      FIG. 3  is substantially a cross-sectional view of the cutting tool shown in  FIG. 1 , the cutting edges being shown to be actuated. 
           [0011]      FIG. 4  is substantially a cut-away and close up view showing the activation of the cutting edges. 
           [0012]      FIG. 5  is substantially a side perspective view of a print toner cartridge for which the cutting tool of the present invention may be used. 
           [0013]      FIG. 6  is substantially another side view of the print toner cartridge shown in  FIG. 5 . 
           [0014]      FIG. 7  is substantially another side view of the print toner cartridge shown in  FIG. 5  showing a perpendicular wall within a drum gear. 
           [0015]      FIG. 8  is substantially a front view of the cutting tool of the present invention being used to remove a drum from the waste hopper. 
           [0016]      FIG. 9  is substantially a front view of the cutting tool of the present invention being used to remove the drum. 
           [0017]      FIG. 10  is substantially a perspective view of the drum substantially detached from the cartridge by the cutting tool of the present invention. 
           [0018]      FIG. 11  is substantially a side view of the drum and the drum gear cut apart by the cutting tool of the present invention. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0019]    In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part of this application. The drawings show, by way of illustration, specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. 
         [0020]    The order in which the steps are presented below is not limited to any particular order and does not necessarily imply that they have to be performed in the order presented. It will be understood by those of ordinary skill in the art that the order of these steps can be rearranged and performed in any suitable manner. It will further be understood by those of ordinary skill in the art that some steps may be omitted or added and still fall within the spirit of the invention. 
         [0021]    Referring to  FIG. 1 , the present invention includes a cutting device  30 . The cutting device  30  preferably includes a drill end  32 . The drill end  32  is preferably configured to be rotated to make a hole on a part of a drum gear, which is a structure that connects the drum to the printer and allows the drum to rotate when the printer is in operation (not shown). Cutting device  30  preferably also includes a drill shaft  34  extending from a non-pointed side of the drill end  32 . The drill shaft  34  preferably defines a horizontal plane A and a vertical plane B. The drill shaft  34  preferably defines a recess  36  extending from side to side or laterally. The recess  36  preferably lies on the horizontal plane A. The height of the recess  36  preferably spans the entire vertical plane B of the drill shaft  34 . 
         [0022]    A pair of moveable cutting edges  38   a  and  38   b  is preferably positioned to move in and out of the recess  36 . The pair of movable cutting edges  38   a  and  38   b  is preferably positioned to move in the direction that is opposite to each other&#39;s direction of movement. Each cutting edge  38  preferably includes a structure with substantially pointed edge, as shown in  FIG. 1 . The level of the sharpness or the dullness of the pointed edge may be varied depending on the efficiency of the cutting and the smoothness of the cut surface the user desires. The number and position of the cutting edges around the shaft may also be varied. 
         [0023]    Cutting device  30  preferably further includes a stop collar  40  attached to a portion of the drill shaft  34  where the recess  36  runs. The stop collar  40  preferably surrounds the outer surface of the drill shaft  34  and covers a portion of the recess  36 . The stop collar  40  preferably rotates with the drill shaft  34 . The stop collar  40  is shown to be circular in shape in  FIG. 1 . However, the stop collar  40  may be designed with various shapes. 
         [0024]    The position of the stop collar  40  on the drill shaft  34  is preferably adjacent to the cutting edges  38   a  and  38   b  and in between an actuating mechanism  44  and the cutting edges  38   a  and  38   b . The stop collar  40  preferably includes a stop surface  42 , which is preferably substantially flat and configured to abut a part of the cartridge (not shown). The distance between the cutting edges  38   a  and  38   b  and the stop collar  40  is preferably predetermined depending on where on the drum or the drum gear the cutting device is designed to make the cut. Once the location of the cut is determined, the distance between the location of the cut and the part of the cartridge to which the stop surface  42  will abut can be calculated. The calculated distance may be used in positioning the stop collar  40  on the drill shaft  34 . That is, the calculated distance may be used as the distance between the cutting edges  38   a  and  38   b  and the position of the stop surface  42  on the drill shaft  34 . It can be realized that the cutting device  30  of the present invention provides a way to cut in a manner where the location of the cut may be adjusted and may be determined with precision. 
         [0025]    The drill shaft  34  and the recess  36  therein preferably extend sideways past the location of the stop collar  40 . Substantially adjacent to the stop collar  40  and substantially opposite the drill end  32  on the drill shaft  34  is preferably an actuating mechanism  44  for the cutting edges  38   a  and  38   b , which is discussed further below. The drill shaft  34  preferably includes an end  45  opposite the drill end  32 , which preferably includes a drill attachment tip  46  attached thereto. The drill attachment tip  46  preferably includes a non-circular periphery such that an electric drill (not shown) may easily grasp the tip  46  and electrically rotate the drill shaft  34 . 
         [0026]    With reference now to  FIG. 2 , the actuating mechanism  44  for the cutting edges  38   a  and  38   b  is shown and preferably includes cutter arms  48   a  and  48   b , arm actuation device  56 , actuation device handle  58 , and actuation device stop collar  60 . Each cutting edge  38   a  and  38   b  is preferably integral to or a part of a corresponding cutter arm  48   a  and  48   b . Each cutter arm  48  preferably includes a first component  50   a  or  50   b , which is preferably positioned within the confines of the drill shaft  34 . 
         [0027]    First components  50   a  and  50   b  preferably extend to their respective second components  52   a  or  52   b , which are preferably positioned at an angle relative to the first components  50   a  and  50   b . In the preferred embodiment, the second component  52  is preferably at an angle between 90-180 degrees from the first component  50 . Substantial portions of the second components  52  preferably project out of the confines of the drill shaft  34  through the recess  36 . Each cutter arm  48  is preferably attached to the drill shaft  34  via a mechanical pin  54   a  or  54   b  positioned within the confines of the recess  36  and attached to the interior wall of the drill shaft  34 . Each cutter arm  48  may preferably pivot around its respective mechanical pin  54 . 
         [0028]    With continued reference to  FIG. 2 , each second component  52  of the cutter arm  48  is preferably moveably attached to the arm actuating device  56  from an end that is distal and opposite from the cutting edges  38 . Each of said second component end preferably defines a lateral recess  62   a  and  62   b  extending from side to side. The arm actuating device  56  preferably attaches to each second component via a mechanical pin  64   a  or  64   b  that passes through the recess  62   a  or  62   b  and that is attached to the arm actuating device  56 . The mechanical pin  64  is preferably configured to slide within the recess  62  when the actuating device  56  is operated to activate the cutting edges  38 . 
         [0029]    The actuating device  56  is preferably a structure that defines a cylindrical recess configured to accommodate the drill shaft  34 . The drill shaft  34  is preferably inserted through this cylindrical recess to allow the actuating device  56  to slide sideways on the drill shaft  34 . The actuating device may be made with various shapes. The actuating device  56  is preferably attached to one end of a biasing device  66 . The other end of the biasing device  66  is preferably attached to the stop collar  40 . It can be realized from  FIG. 2  that the actuating device  56  is preferably biased to move toward the stop collar  40  in the deactivated position. In the deactivated position, the biasing device  66  also positions the actuating device  56  and the mechanical pin  64  toward the stop collar  40 . First component  50   a  is preferably biased to pivot counterclockwise. First component  50   b  is preferably biased to pivot clockwise. In other words, in the deactivated position, cutter arms  48   a  and  48   b  are biased to pivot toward each other. As a result, the cutting edges  38   a  and  38  are preferably positioned to be contained inside the confines of the drill shaft  34  when the actuating device  56  is deactivated. 
         [0030]    With continued reference to  FIG. 2 , an actuation device stop collar  60  that wraps around and is attached to the drill shaft  34  may be provided to limit the sliding distance of the actuating device  56 . The actuating device  56 , the stop collar  60 , and the stop collar  40  preferably wrap around the drill shaft  34  rotates with the drill shaft  34 . The actuation device stop collar  60  is preferably positioned on the drill shaft  34  at a predetermined distance relative to the actuating device  56 . The predetermined distance is preferably based on the desired maximum height of the cutting edge  38  when the cutting device  30  will be operated. The height of the cutting edge  38  that will project out of the recess  36  is directly proportional to the distance between the actuation device stop collar  60  and the actuating device  56 . It can be realized that the height of the cutting edge  38  from the drill shaft  34  determines the depth of the cut created by the cutting edge  38 . 
         [0031]    Referring now to  FIG. 3 , the actuating mechanism  44  may be activated as follows. A user may hold a handle  58  attached to the actuating device  56  and pull said handle  58  towards the stop collar  60  as indicated by the arrow. The handle  58  preferably includes an elongate body and a circular body attached thereto, which is preferably configured to surround the actuating device  56 . The periphery of the actuating device  56  is preferably attached to the circular body, such that when the handle  58  is pulled, the actuating device  56  is carried by the circular body while, at the same time, when the shaft  34  is rotated, the actuating device  56  rotates with the shaft  34  around the circular body of the handle  58 . 
         [0032]    Thus, when the handle  58  is pulled towards the stop collar  60 , the actuating device  56  moves along with the handle  58 , the biasing device  66  is stretched, and the mechanical pin  64  contained in the recess  62  defined by the cutter arm  48  is moved toward the actuating device  56 . The cutter arm  48  preferably pivots around mechanical pin  54  and causes first component  50   a  to pivot clockwise and first component  50   b  to pivot counterclockwise. The result is that when the actuating mechanism is activated, cutting edges  38   a  and  38   b  are caused to pass through the recess  36  and project out of the drill shaft  34 , as indicated by the arrow and as shown in  FIG. 4 . It can be realized that the cutting edges  38   a  and  38   b  are now in a position to contact the objects introduced to them. An electric drill may be used to rotate the drill shaft  34  and the cutting edges  38   a  and  38   b  to cut an object. For instance, the cutting edges  38   a  and  38   b  may be used to cut a portion of a drum gear that holds the drum to a cartridge thereby allowing the removal of the drum from the cartridge ( FIGS. 8 and 9 ). 
         [0033]    In addition to the various embodiments of the cutting tool  30 , the present invention also includes methods of remanufacturing a toner cartridge, which will now be discussed. In the discussion below, laser printer cartridges from Hewlett Packard company having model numbers HP 1600, HP 2600, and HP 2605 are used as examples for ease of description. The methods are by no means limited to the remanufacturing of laser printer cartridges from Hewlett Packard company. The methods may be executed in remanufacturing of cartridges of various types of printers from various companies. As shown in  FIGS. 5 and 6 , a used toner cartridge typically includes a toner hopper  20 , which is usually refilled with toner during remanufacturing and a waste hopper  21 , which may be cleaned during remanufacturing. The drum of the used toner cartridge may also need to be replaced. To access the drum, the toner hopper  20  and the waste hopper  21  are preferably separated by detaching the screws  22   a  and  22   b , springs  23   a  and  23   b , and pins  24   a  and  24   b.    
         [0034]    In  FIGS. 7-11 , a typical toner cartridge drum  26  includes a cylindrical body  25  with hollow interior (not shown). The drum typically includes a drum gear  27  configured to be connected to the printer (not shown) and allow the drum the rotate when the printer is in operation. The drum gear may have a cylindrical body  28  and are attached to both ends of the drum body  25 . Some drum gears include a gear wall  29  ( FIG. 7 ) positioned perpendicular to the cylindrical body of the drum gear. It can be realized that when the drum gear is attached to the drum and the drum is attached to the cartridge, the gear wall  29  may serve to block access to the hollow interior of the cylindrical drum body. The gear wall  29  may also block access to a gear portion in between the gear wall and the drum. 
         [0035]    Referring now to  FIG. 8 , once the toner hopper and the waste hopper are separated, the cutting tool  30  may be used to remove the drum  26  from the cartridge  31 . The cutting tool  30  is preferably attached to an electric drill  33 . The electric drill  33  preferably allows the drill end  32  of the cutting tool to puncture and enter through the gear wall  29 . Once drill end  32  enters through the gear wall  29 , the drill shaft  34  also enters through the gear wall and in the hollow interiors of the cylindrical bodies of the gear and the drum. It can be realized that if the drum gear does not have a gear wall, an embodiment of the cutting tool need not include a drill end  32  attached to the drill shaft  34 . 
         [0036]    Referring now to  FIG. 9 , once the drill shaft  34  is inserted through the hollow interior of the drum gear, the stop collar  40  preferably abuts the cartridge portion  31  to prevent further forward motion of the drill end and shaft. The user may activate the actuating mechanism  44  by pulling the handle  30  towards the electric drill  33  while keeping the stop collar  40  abutted to the cartridge portion  31 . The user may continue pulling if the handle in the direction indicated preferably until the actuating device  56  abuts the stop collar  60 . As the user pulls the handle in the direction indicated, the cutter arm  48   a  preferably pivots clockwise and cutter arm  48   b  preferably pivots counterclockwise (not shown in  FIG. 9 ). The result is that the cutting edges  38   a  and  38   b  are caused to pass through the recess  36  and project out of the drill shaft  34  (not shown in  FIG. 9 ). The cutting edges  38   a  and  38   b  consequently contact the interior wall of the cylindrical body of the drum gear  27 . The electric drill preferably rotates the cutting edges  38   a  and  38   b , which eventually cuts the drum gear  27  at the area indicated by arrow C. The area indicated by arrow C is preferably a gear portion in between the drum body  26  and the cartridge  31 . The cut made by the cutting edges  38   a  and  38   b  are preferably around the circumference or the periphery of a gear portion (as shown in  FIG. 11 ). 
         [0037]    It can be appreciated that, with the present invention, the precision of the location of the area where the cutting edges  38  and  38   b  will make a cut can be attained by adjusting the distance between of the stop collar  40  relative to the cutting edges  38   a  and  38   b . Referring now to  FIGS. 10 and 11 , the drum  26  may now be detached from the cartridge  31 . It can be appreciated from  FIG. 10  that the cutting device  30  of the present invention is able to cut the gear  27  of the drum from the hollow interior of the cylindrical body  28  of the gear and cleanly cut the periphery of the cylindrical body  28  of the drum gear  27  ( FIGS. 10 and 11 ). 
         [0038]    It can now be realized that the present invention facilitates the removal of the drum with little or no requirement of having to break any portion of the cartridge  31 . This advantage is highly beneficial in the remanufacturing of cartridges, as the appearance of the cartridge is preserved. Additionally, since the removal of the drum by the present invention reduces or avoids having to break any portion of cartridges, the present invention avoids extraneous steps of having to put back broken cartridges. It can further be realized that the present invention provides a new cutting tool and technique for cutting hollow objects from its hollow interior. It can also be realized that the present invention provides a new technique for efficiently removing and replacing a toner cartridge drum, which may be practiced when remanufacturing a previously used toner cartridge. 
         [0039]    Although the description above contains many specifications, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. For example, various mechanical fasteners known in the art may be used in lieu of the mechanical pins described herein. The cutting device may be used for cutting hollow objects from the hollow interior side of the objects other than toner cartridge drums. The shapes of the stop collars and the actuating device may be varied. The shapes and number of cutting edges and cutter arms may be varied. The invention is capable of other embodiments and of being practiced and carried out in various ways. The invention is not limited in its application to the details of the construction and to the arrangement of the components set forth in the above description or as illustrated in the drawings.