Abstract:
Apparatus and method for protecting a print cartridge that eliminates an adhesive strip. The print cartridge protector uses a hook shaped end inserted into a slot defined by the print cartridge to keep the print cartridge protector in engagement with the print cartridge. The opposite end may be held in place by another hook shaped end or a loop inserted in another end of the print cartridge.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of Invention 
     This invention relates to abrasion resistive packaging, such as packaging to protect a photoreceptor of a print device. 
     2. Description of Related Art 
     In current printing applications, print cartridges are incorporated in printing devices. The print cartridges contain a printing material, such as toner. Typically, the print cartridges are replaceable, and the print cartridges are discarded when they run out of toner, and a new print cartridge is inserted into the print device. The disposability of the print cartridges requires that new print cartridges be shipped. 
     SUMMARY OF THE INVENTION 
     Portions of the print cartridge can be damaged during shipping or storage prior to use. For example, the photoreceptor is sensitive to abrasion. Thus, it is desirable to protect the print cartridge so as to protect the photoreceptor from damage. 
     In printing applications, photoreceptor drums are used to transfer toner from a storage area to a recording medium. These photoreceptor drums are sensitive to abrasion which may wear off the photoreceptor coating. One method of protecting these print cartridges is to use heavy paper during storage and transport to prevent damage to the photoreceptor drum. 
     A photoreceptor protector covers the photoreceptor drum which is contained in a print cartridge. The print cartridge is used in various models of printers, copiers, facsimile machines to produce output on the recording medium. Print cartridges need replacement on a regular basis as the print cartridges hold toner and the toner is used to make recordings on a recording material. The toner thereby runs out and either needs to be replenished or the print cartridge needs to be replaced. 
     One example of photoreceptor protectors utilize heavy paper with at least one adhesive zone to attach the heavy paper to the print cartridge. The photoreceptor protector is then removed by peeling the heavy paper and adhesive off of the print cartridge to expose the photoreceptor drum. 
     The adhesive used to attached the photoreceptor protector to the print cartridge can be problematic. The adhesive can be difficult to apply. Errors in applying the adhesive include the adhesive being applied to the wrong area or in an excessive amount. Further, once applied, the adhesive will not always be completely removed from the print cartridge when the photoreceptor protector is removed. 
     This invention provides systems and methods for protecting the photoreceptor drum without using adhesive. The adhesives are eliminated by the use of a hook type fold feature. The hook type fold feature holds the end of the photoreceptor protector in place without the use of adhesives. Thus the systems and methods of this invention reduce the number and amount of adhesives needed during manufacture. Further, the systems and methods of this invention make for a simpler photoreceptor protector that is more environmentally friendly because of the lack of adhesives. 
     The systems and methods according to this invention take advantage of the discovery that print cartridges have areas capable of receiving a portion of a folded photoreceptor protector that will retain the portion of the photoreceptor protector without the need for adhesive. 
     Lastly, the systems and methods of this invention allow for easier removal of the photoreceptor protector from the print cartridge because the person removing the photoreceptor protector does not have to remove the adhesive. 
     These and other features and advantages of this invention are described in or apparent from the following detailed description of the preferred embodiments. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will be described with reference to the accompanying drawings, in which like elements are labeled with like numbers and in which: 
     FIG. 1 shows an exemplary embodiment of the photoreceptor protector in a stage of construction according to this invention; 
     FIG. 2 is another exemplary embodiment of the photoreceptor protector as fully assembled and prepared for installation on a print cartridge; 
     FIG. 3 is a related art diagram of a photoreceptor protector as it is prepared for installation on a print cartridge; 
     FIG. 4 is a functional block diagram of the print cartridge and photoreceptor protector with the photoreceptor protector installed; 
     FIG. 5 is a functional block diagram of a perspective view of the photoreceptor protector installed on the print cartridge; and 
     FIG. 6 is a functional block diagram of a related art photoreceptor protector installed in the print cartridge. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     FIG. 1 shows an exemplary photoreceptor protector  100  according to this invention after the source material has been cut and scored. The exemplary photoreceptor protector  100  is first formed with a pull tab  110 . The pull tab  110  has pull arrow  108  printed on it. Photoreceptor protector  100  is the n formed with fold lines  111 ,  117 ,  119 ,  121 ,  123 ,  131  and  141 . Adhesive is applied to tape adhesive region  114  and scorings are placed at scoring marks  124  and  125 . 
     Photoreceptor protector  100  is, for example, bent along lines  121  and  119  to form the top insert region  120 , bent along line  117  to form the top holding region  118  and bent along line  123  to form the top holding region  122 . The tape adhesive region  114 , between dashed lined  113  and  115  has adhesive applied before being attached to the photoreceptor cover region  130 . Thus, the top insert region  120  may be made by using an adhesive strip in the top adhesive region  114  to attach the photoreceptor protector back to itself. Photoreceptor protector  100  may be bent along line  131  to form the bottom insert region  140  and bent along line  141  to form the bottom holding region  142 . 
     Photoreceptor protector  100  as shown in the exemplary embodiment is made of paper. However, other embodiments such as plastic, plastic impregnated paper, foam, cardboard or any other material now known or later developed that can be used for the photoreceptor protector  100 . For example, the photoreceptor protector  100  can be constructed at least partially of foam, which will also protect against impacts. 
     Further, in the exemplary embodiment the photoreceptor protector  100  is flexible, to protect against abrasion only. However, various exemplary embodiments can also be rigid in portions such that the print cartridge is protected against moisture and/or impact damage. 
     Photoreceptor cover region  130  is shown with a notched configuration such that bottom insert region  140  is smaller in width than top insert region  120 . This is done to show an exemplary preferred embodiment. Bottom insert region  140  may be the same width as top insert region  120  or wider than top insert region  120  in other various exemplary embodiments. 
     The top adhesive region  114  uses adhesive in the preferred exemplary embodiment. However, other fastening materials and methods such as staples, clips and melting may be used in other exemplary embodiments. 
     Further, scoring marks  124  and  125  in the preferred embodiment are for the convenience ensuring that photoreceptor cover region  130  is as straight as possible and may be eliminated or moved in other various exemplary embodiments. 
     Even further, bend lines  111 ,  117 ,  119 ,  121  and  123  and top spacer region  116  may be long or short to space pull tab  110  at any space for the operator to pull tab  110  and disengage the photoreceptor cover  100 . 
     Pull arrow  108  is shown in the preferred embodiment for the convenience of the user. Pull arrow  108  may be moved, changed or eliminated in various exemplary embodiments. 
     Bottom holding region  142  and pull tab  110  are shown with tapered ending zones as a preferred embodiment. Bottom holding region  142  and pull tab  110  may be square or more radically tapered in other various exemplary embodiments. 
     FIG. 2 shows an example of a photoreceptor protector  100  folded into its final shape. Pull tab  110  is bent away from the photoreceptor cover region  130  and top insert region  120  is formed by the folding back top holding regions  118  and  122 . Bottom holding region  140  and  142  are fold formed by folding along lines  131  and  141  to form the preferred hook shape. 
     The top region  120  is, for example, inserted in the top end of the print cartridge with the pull tab  110  facing away from the print cartridge. Photoreceptor cover region  130  then lays along the outer surface of the print cartridge  10  covering the photoreceptor  20 . Bottom insert region  140  is inserted in an opposite end of the print cartridge where bottom holding region  142  is bent up to hold bottom insert region  140  along the bottom side of the print cartridge thereby holding the photoreceptor cover region  130  in a position to protect the photoreceptor  20 . 
     FIG. 3 shows a related art photoreceptor protector  200  that utilizes top insert region  220  held by top holding regions  222  and  218 . The photoreceptor is covered by photoreceptor cover region  230  and held in place by adhesive strip  240 . Pull tab  210  is then situated below the adhesive strip  240  for the user to remove the photoreceptor protector  200 . 
     The photoreceptor protector  200  uses a pressure sensitive adhesive in the adhesive strip  240  to attach the cover  200  to the print cartridge  10 . If operators are not careful with the placement of this adhesive strip on the cartridge, several problems may arise, resulting in the cover sticking either too well or not well enough. Also, if there are any oils or mold on the cartridge, the adhesives do not hold well on the cartridge  10 . If the photoreceptor protector  200  comes loose, the adhesive strip  240  may cause catastrophic cartridge failure by adhering to the photoreceptor  20 . The invent ion eliminates the adhesive strip  240 . This is accomplished, for example, by lengthening the drum cover region  130  and adding bottom insert region  140  and bottom holding region  142  so that the end cover hooks into the cartridge  10  and is secured in place. 
     Both the claimed photoreceptor protector  100  and the related art photoreceptor protector  200  use a top insert region  120  and  220  on the photoreceptor protector which “expands” to fill a gap in the print cartridge. 
     The related art design is expensive due to the cost of the adhesive strip  240 . The systems and methods of the invention improve on the related art photoreceptor protector  200  due to the elimination of the adhesive strip region  240 . Elimination of this bottom adhesive region  240  creates multiple savings due to a shorter assembly line, fewer adhesives used and less materials cost. 
     FIG. 4 shows an exemplary embodiment of the photoreceptor protector  100  installed in an exemplary print cartridge  10 . As shown in FIG. 4, arrow  2  indicates the up direction for the print cartridge  10 . 
     The photoreceptor protector  100  covers the photoreceptor  20 . The top insert region  120  has top holding region  118  resting against front cover  30  and top holding region  122  resting against print cartridge edge  40 . The pull tab  110  juts out away from the print cartridge  10  such that a user may pull the pull tab  110  to remove the drum cover  100 . The photoreceptor cover  130  extends down from the top insert region  120  to cover the photoreceptor  20  towards the bottom insert regions  140 . Bottom insert region  140 , for example, is inserted in between back cover  50  and holder  60  such that bottom insert region  140  is held in place by bottom holding region  142  that is bent. 
     Top insert region  120  has top holding regions  118  and  122  resting on print cartridge regions  30  and  40 . However, top insert region  120  can fit into any opening in the top of a print cartridge such that top holder regions  118  and  122  serve to keep the photoreceptor protector  100  in place. Further, bottom insert region  140  is shown sandwiched between back cover  50  and holder  60 . However, bottom insert region  140  can be inserted into any appropriate area at the bottom of the print cartridge  10  such that the bottom holding region  142  can be bent and hold bottom insert region  140  in place. 
     FIG. 5 shows an exemplary embodiment of the drum cover  100  on the print cartridge  10  from a perspective view. Arrow  2  indicates the up direction corresponding to the up direction shown in FIG.  4 . Drum cover  100  has drum cover photoreceptor cover region  130  and pull tab  110  showing. 
     FIG. 6 shows an related art diagram of the photoreceptor protector  200  installed in the print cartridge  10 . As shown in FIG. 6, arrow  2  indicates the up direction for the print cartridge  10 . 
     The photoreceptor protector  200  covers the print cartridge  10  such that the photoreceptor  20  is protected. The top insert region  220  has top holding region  218  resting against front cover  30  and top holding region  222  resting against print cartridge edge  40 . The pull tab  210  juts out away from the print cartridge  10  such that a user may pull the pull tab  210  to remove the drum cover  200  by peeling off the adhesive strip  240 . 
     While this invention has been described in conjunction with specific embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention.