Abstract:
A modification for an imaging cartridge is provided for use with certain aftermarket or non-OEM cartridge drive mechanisms. At least one wall of a cartridge guiding member is removed to increase a clearance between the guiding member and the cartridge drive mechanism.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of and priority to U.S. provisional patent application No. 62/128,769, filed Mar. 5, 2015, the entire contents of which are hereby incorporated by reference herein. 
     
    
     BACKGROUND 
       [0002]    The present disclosure relates to consumable cartridges used in image forming apparatuses, and more specifically to modifications and methods for making modifications to such cartridges to accommodate aftermarket cartridge drive components. 
         [0003]    Aftermarket suppliers of imaging consumables, such as toner cartridges for imaging devices, configure their cartridges to be compatible with the drive mechanisms provided on name brand imaging devices. In many instances, suppliers of aftermarket consumable cartridges modify their cartridges to be different from original equipment manufacturer (OEM) cartridges, for example to increase page yield, to make cartridges compatible with additional or different imaging devices, to improve performance with other non-OEM components (such as toner), and the like. 
         [0004]    Some aftermarket suppliers remanufacture OEM cartridges. These suppliers collect or otherwise acquire used OEM cartridges, disassemble, clean, and inspect the components, replace any parts that are damaged or worn beyond specified tolerances, and reassemble the components into a complete cartridge with a new supply of toner. Remanufactured cartridges offer many benefits, including a reduced cost compared to OEM cartridges and the diversion of waste material (i.e. the spent OEM cartridge) from the landfill. Like other aftermarket suppliers of imaging consumables, remanufacturers may modify the used cartridges they obtain or use parts configured differently from the OEM cartridge parts in order to obtain one or more of the benefits described above. 
         [0005]    One example of an OEM cartridge that may be remanufactured in the manner discussed above is shown and described in U.S. Pat. No. 8,121,517 (“the &#39;517 patent”), the entire contents of which are hereby incorporated by reference herein. The &#39;517 patent discloses a process cartridge that may be mounted within a printer. With reference to  FIGS. 1 and 2 , which correspond to  FIGS. 29 and 32 , respectively, of the &#39;517 patent, the cartridge includes a coupling member  150  that is pivotally mounted to the end of an organic photoconductive drum  20  rotatably supported within the cartridge. The coupling member  150  is mounted to the drum  20  using a ball-and-socket configuration, including spherical member  160  which functions as the ball and is received by a socket defined by a drum flange  151  mounted in the end of the drum  20 . The coupling member  150  also includes a reduced diameter intermediate part  150   c  that extends away from the spherical member  160  and a driven portion  150   a  of relatively enlarged diameter and including force receiving portions  150   e  generally in the form of teeth or dogs configured to receive driving force from the printer. 
         [0006]    The coupling member  150  extends through an opening in the side of the cartridge and is surrounded by what the &#39;517 patent describes as a “regulating portion”  170 . The regulating portion  170  functions to guide the cartridge into the printer and to limit the extent of pivotal movement of the coupling member  150  in various directions. According to the &#39;517 patent, the regulating portion  170  includes a central opening defined in part by a first arcuate portion  170   a  through which intermediate part  150   c  of the coupling member  150  extends. The regulating portion  170  includes an inclination regulating portion  170   g  that permits angular movement generally in the rearward, downward, and forward directions within a predetermined range of around 20 to 30 degrees depending on the specific orientation of the coupling member  150 . 
         [0007]    The regulating portion  170  also includes a regulating projection  170   c  that projects in the axial direction a distance beyond the inclination regulating portion  170   g.  The regulating projection  170   c  extends over and above the first arcuate portion  170   a  and includes a flat surface portion  170   e  and a second arcuate portion  170   d  that cooperate to limit pivotal movement of the coupling member  150  in the upward and rearward directions to just a few degrees. The &#39;517 patent refers to the position where the coupling member  150  is substantially axially aligned with the organic photoconductive drum to which it is attached as the “rotational force transmitting angular position.” This position is associated with the cartridge being installed in the printer such that the coupling member  150  is positioned to receive driving rotational force from the printer drive mechanism.  FIG. 2 , which corresponds to  FIG. 32  of the &#39;517 patent, illustrates how the coupling member  150  moves from an angled or “pre-engagement angular position” as shown at (a) to the axially aligned rotational force transmitting angular position as shown at (d) as the cartridge is installed in the printer. When the cartridge is removed from the printer the coupling member  150  moves from the axially aligned rotational force transmitting angular position to the angled pre-engagement angular position. Pivotal movement of the coupling member  150  between these positions during insertion and removal of the cartridge facilitates engagement with and disengagement from the printer drive mechanism. 
       SUMMARY 
       [0008]    In some aspects, a method of modifying a process cartridge includes obtaining a process cartridge including a guide member having a central body portion with an opening defining an axis and a regulating projection positioned substantially adjacent to the opening and extending axially from the central body, the regulating projection including an inner wall and an outer wall spaced radially outwardly from the inner wall, and eliminating the inner wall to increase a radial distance between the axis and the regulating projection. 
         [0009]    The outer wall may be an outer arcuate wall arranged substantially concentrically with respect to the axis. The inner wall may include a flat surface portion and an arc portion arranged substantially concentrically with respect to the axis, and eliminating the inner wall may include eliminating the flat surface portion and the arc portion. The regulating portion may further include a joining wall extending between the arc portion and the outer arcuate wall, and the method may further include eliminating the joining wall. Eliminating the inner arcuate wall may include removing the inner wall from the guide member. The outer wall may include an inner arcuate surface facing the axis and having an inner arcuate surface radius, and removing the inner wall may include performing a cutting operation using a rotary cutter having a radius slightly less than the inner arcuate surface radius. Eliminating the inner arcuate wall may include replacing the guide member with a second guide member that does not include the inner wall. The method may further include installing an OPC drum into the process cartridge. The OPC drum may include a replacement gear and a replacement coupling member, and the replacement coupling member may be mounted for axial movement relative to the gear between an extended position and a retracted position. Installing the OPC drum into the process cartridge may include positioning the coupling member within the opening. 
         [0010]    In other aspects, a method of modifying a process cartridge includes obtaining a process cartridge including a guide member having a central body portion with an opening defining an axis and a regulating projection positioned substantially adjacent to the opening and extending axially from the central body. The regulating projection includes an innermost arcuate portion spaced a radial distance from the axis. The method also includes modifying the guide member to increase the radial distance between the innermost arcuate portion of the regulating projection and the axis. 
         [0011]    Before modifying the guide member the radial distance may be R1, and after modifying the guide member the radial distance may be R2. In some configurations, R2 may be at least about 20% greater than R1. In other configurations, R2 may be between about 20% and about 100% greater than R1. In still other configurations, R2 may be about 50% greater than R1. The regulating projection may include an outer arcuate wall arranged substantially concentrically with respect to the axis, and an inner wall including an arc portion arranged substantially concentrically with respect to the axis. Modifying the guide portion may include eliminating the inner wall. Before modifying the guide member the arc portion may define the innermost arcuate portion and after modifying the guide member an inner surface of the outer arcuate wall may defines the innermost arcuate portion. Modifying the guide member may include performing a cutting operation on the regulating portion. Modifying the guide member may also include replacing the guide member with a second guide member. The method may further include installing an OPC drum into the process cartridge. The OPC drum may include a replacement gear and a replacement coupling member, and the replacement coupling member may be mounted for axial movement relative to the gear between an extended position and a retracted position. Installing the OPC drum into the process cartridge may include positioning the coupling member within the opening. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a perspective view illustrating a relation between a main assembly guide of a prior art printer and a coupling of a prior art process cartridge. 
           [0013]      FIG. 2  is a perspective view illustrating a process of the prior art coupling of  FIG. 1  engaging a prior art driving shaft. 
           [0014]      FIG. 3  is a side view of a prior art cartridge coupling member and inclination regulating portion. 
           [0015]      FIG. 4  is a perspective view of a replacement OPC drum gear and coupling member. 
           [0016]      FIG. 5  is a side view of a portion of a process cartridge that has been modified in accordance with the present invention. 
           [0017]      FIG. 6  is a perspective view of the portion of the modified process cartridge of  FIG. 5 . 
           [0018]      FIG. 7  is a side view of a modified guide member for a process cartridge. 
           [0019]      FIG. 8  is a perspective view of the modified guide member of  FIG. 7 . 
       
    
    
       [0020]    Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. 
         [0021]    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 
       [0022]      FIG. 3  illustrates one type of prior art regulating portion  170  that may be modified or replaced in accordance with the teachings of the present invention. Although other modifications may also be made, the primary modification associated with the present invention involves modification to the regulating projection  170   c  to provide additional clearance for coupling members that, unlike the prior art coupling member  150 , generally do not pivot and/or are not inclinable relative to the axis of the drum  20 . As shown in  FIG. 3 , the prior art regulating projection  170   c  includes an outer arcuate wall  170   m,  and an inner wall  170   k  comprising the flat surface portion  170   e  and second arc part  170   d  described above. The regulating projection  170   c  also includes a substantially straight joining wall  170   j  that extends between a rear edge of the second arc part  170   d  and a rear edge of the outer arcuate wall  170   m.  As discussed further below, modification of the illustrated regulating projection  170   c  includes removing the inner wall  170   k  and the joining wall  170   j.    
         [0023]      FIG. 4  illustrates a replacement coupling member  250  and gear  252  for installation into the end of an OPC drum  20  during remanufacturing of a cartridge. The illustrated coupling member  250  and gear  252  are disclosed in U.S. Pat. No. 9,170,549, the entire contents of which are hereby incorporated by reference herein. The coupling member  250  is mounted for axial movement relative to gear  252  between an extended position (shown in  FIG. 4 ) and a retracted position and is biased toward the extended position. The coupling member  250  is also rotatable relative to the gear  252  through a rotation that is less than one rotation about the axis, after which further rotation of the coupling member  250  will cause rotation of the gear  252 . 
         [0024]    The coupling member  250  includes an engagement portion  254  configured for engagement with the drive mechanism of the printer. The engagement portion  254  includes a generally circular central portion  256  defining a circular recess  258 , and a pair of diametrically opposed radial projections  260  extending outwardly from the central portion  256 . The engagement portion  254  also includes a pair of axially extending drive lugs  262  for receiving driving force from the printer drive. The drive lugs  262  each include a radially inner edge substantially aligned with the outer edge of the circular recess  258 , and a radially outer edge that is positioned along a respective one of the radial projections  260 . A convex radius  264  extends continuously around the outer periphery of the engagement portion  254 . The convex radius  264  is provided such that during installation of a cartridge including the coupling member  250 , the convex radius  264  contacts the drive mechanism of the printer and causes the coupling member  250  to be urged in an axial direction toward the retracted position. Movement of the coupling member  250  toward the retracted position facilitates engagement of the engagement portion  254  with the drive mechanism of the printer. 
         [0025]    It should be appreciated that the coupling member  250  of  FIG. 4  is one example of a potential replacement for the pivoting coupling member  150  discussed above. Several other replacement coupling members have also been proposed, including coupling members that pivot to a far more limited degree than the coupling member  150 , coupling members where only relatively small portions of the coupling member, such as the engagement portion, are able to pivot or incline relative to the drum axis, coupling members that are able to shift radially away from the drum axis without pivoting or with a relatively small amount of pivoting, and the like. These and other replacement coupling member configurations may all be combined with the teachings of the present invention to facilitate and/or improve engagement and disengagement of the replacement coupling member with the printer drive mechanism. 
         [0026]    Referring now to  FIGS. 5-8 , a modified regulating portion  170   z  in the form of a guide member  300  is shown secured to one side of a process cartridge. The guide member  300  is heat staked and/or sonically welded to the process cartridge as at  304 , but may also be secured to the process cartridge using screws, rivets, or other fastening methods. In the illustrated example the coupling member  250  is shown extending through the guide member  300  for engagement with the drive mechanism of a printer. 
         [0027]    The guide member  300  includes a central body portion  308  defining a generally circular opening  312  defining an axis  316 . The opening includes at least one substantially arcuate portion  320  having a first radius R1. In the illustrated configuration shown, for example, in  FIG. 1 , the first radius R1 of the arcuate portion  320  substantially corresponds to a radius of the second arc part  170   d  of the inner wall  170   k.  A mounting wall  324  extends generally radially outwardly from the central body portion  308  and includes a mounting surface (not visible in  FIGS. 5-8 ) that mates up with a side wall of the process cartridge when the guide member  300  is coupled to the process cartridge. The mounting wall  324  also defines at least one mounting aperture  328  that may be used to secure the guide member  300  to the process cartridge using one or more screws, rivets, heat stakes, sonic welding, bonding and the like. The guide member  300  also includes a guide wall  332  extending generally radially outwardly from the central body portion  308  and generally oriented at an acute included angle with respect to the mounting wall  324 . The guide wall  332  includes at least one guide surface  336  that engages slots, grooves, or other features provided in the printer when the guide member  300  (attached to a process cartridge) is installed into the printer. In the illustrated construction the guide surface is oriented substantially perpendicular to the mounting surface of the mounting wall  324 . 
         [0028]    The guide member  300  also includes an overhanging portion  340  that, in the illustrated configuration, corresponds to a regulating projection  170   c  that has been modified such that substantially only the outer arcuate wall  170   m  remains. More specifically, the overhanging portion  340  may be formed by milling, trimming, cutting, melting, or otherwise removing the inner wall  170   k,  including both the flat surface portion  170   e  and second arc part  170   d,  as well as the straight joining wall  170   j  (see  FIG. 3 ). As a result, the inner surface  170   n  of what was the inner wall  170   k  becomes an innermost arcuate surface  344  of the overhanging portion  340 . The innermost arcuate surface  344  faces the axis  316  and has a second radius R2 that is greater than the first radius R1. In some configurations, the second radius R2 is at least about 20% greater than the first radius R1. In the illustrated configuration, the second radius R2 is about 12 mm and the first radius R1 is about 8 mm. Thus, in the illustrated configuration, the second radius R2 is about 50% greater than the first radius R1. To maintain printer compatibilities, it is preferred for the second radius R2 to be no more than about 100% greater than the first radius R1. 
         [0029]    As shown in  FIGS. 5 and 6 , there are several millimeters of clearance between the innermost arcuate surface  344  and the outermost portion of the convex radius  264  provided on the coupling member  250 . Without the above described modification, clearance between the outermost portion of the convex radius  264  and the inner wall  170   k  of the regulating projection  170   c  is extremely close. Initial reasoning based upon, among other things, the teachings of the &#39;517 patent, suggested that a relatively small clearance between the convex radius  264  and the inner wall  170   k  might facilitate engagement of the coupling member  250  with the printer drive mechanism, for example by preventing excessive deflection of the coupling member in the upward and rearward directions as used for the coupling member  150 . However, the opposite was determined to be true. In many circumstances, particularly during installation and removal of the cartridge, the close clearance between the inner wall  170   k  and the convex radius  264  was found to be preventing the coupling member  250  from moving axially in the manner intended. By increasing the clearance surrounding the convex radius  264  operation of the coupling member  250  is unexpectedly improved. 
         [0030]    In one preferred method of making the guide member  300 , an axial cutter, such as an end mill, having an outer radius slightly less than (for example between about 0.5 mm and 5 mm less than) the radius R2 is selected such that a single axial cut may be used to remove the inner wall  170   k  and the straight joining wall  170   j  (see  FIG. 3 ). In some configurations, additional joining walls may extend between the inner wall  170   k  and the outer wall  170   m  of the original regulating projection  170   c.  Using the above described method of making the guide member  300 , these additional walls may also be removed in a single cutting operation. Another method of making the guide member  300  is to mold or otherwise fabricate a completely new guide member  300 . In this method, the original regulating portion  170  may be removed from the process cartridge and recycled, and the new guide member  300  may be installed in its place. In still other methods of making the guide member  300 , the regulating projection  170   c  may be removed in its entirety, including the outer wall  170   m.  These and other alternative constructions are intended to fall within the spirit and the scope of the present invention. 
         [0031]    Various features of the invention are set forth in the following claims.