Abstract:
Techniques for attaching a replacement chip to an imaging cartridge are described. a method of replacing a component of an imaging cartridge includes: providing the imaging cartridge including a chip and a chip holding structure holding the chip, the chip holding structure including a left upper flange, a right upper flange, a rear retaining member, bottom supporting rails, a left forward retaining element extending from the left upper flange, and a right forward retaining element extending from the right upper flange; removing at least a portion of the left forward retaining element and the right forward retaining element to form a modified chip holding structure; removing the chip from the cartridge; installing a replacement chip in the modified chip holding structure; and attaching the replacement chip to the imaging cartridge.

Description:
[0001]    The present application is a continuation of U.S. patent application Ser. No. 11/479,798 filed Jun. 30, 2006, which is herein incorporated by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    The present invention generally relates to manufacturing, remanufacturing or repairing replaceable imaging components, and more particularly to apparatus and techniques for replacing an electronic circuit. 
         [0003]    In the imaging industry, there is a growing market for the remanufacture and refurbishing of various types of replaceable imaging cartridges such as toner cartridges, drum cartridges, inkjet cartridges, and the like. These imaging cartridges are used in imaging devices such as laser printers, xerographic copiers, inkjet printers, facsimile machines and the like, for example. Imaging cartridges, once spent, are unusable for their originally intended purpose. Without a refurbishing process these cartridges would simply be discarded, even though the cartridge itself may still have potential life. As a result, techniques have been developed specifically to address this issue. These processes may entail, for example, the disassembly of the various structures of the cartridge, replacing toner or ink, cleaning, adjusting or replacing any worn components and reassembling the imaging cartridge. 
         [0004]    Some toner cartridges may include a chip having a memory device which is used to store data related to the cartridge or the imaging device, such as a printer, for example. The imaging device may communicate with the chip using a direct contact method or a broadcast technique utilizing radio frequency (RF) communication. This chip is typically mounted in a location, such as a slot on the cartridge to allow for proper communication between the printer and the toner cartridge when the cartridge is installed in the printer. When the toner cartridge is being remanufactured, as described above, the chip provided by the original equipment manufacturer (OEM), such as Hewlett-Packard or Lexmark, may need to be replaced by a compatible chip developed by a third party. Due to the design of the toner cartridge, a certain part of the cartridge which helps hold the chip in place may need to be permanently removed in order to remove the OEM chip. With the part of the toner cartridge removed, a replacement chip would not be secured to the cartridge when it is installed. Thus, it would be desirable to provide techniques for attaching a replacement chip to such a toner cartridge. 
       SUMMARY 
       [0005]    In one aspect of the present invention a method of replacing a component of an imaging cartridge includes: providing the imaging cartridge comprising a chip and a chip holding structure holding the chip, the chip holding structure including a left upper flange, a right upper flange, a rear retaining member, bottom supporting rails, a left forward retaining element extending from the left upper flange, and a right forward retaining element extending from the right upper flange; removing at least a portion of the left forward retaining element and the right forward retaining element to form a modified chip holding structure; removing the chip from the cartridge; installing a replacement chip in the modified chip holding structure; and attaching the replacement chip to the imaging cartridge. 
         [0006]    A more complete understanding of the present invention, as well as further features and advantages of the invention, will be apparent from the following detailed description and the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  shows a perspective view of a chip holding area of a toner cartridge; 
           [0008]      FIG. 1A  shows a frontal view of the chip holding area of the toner cartridge; 
           [0009]      FIG. 2  shows a perspective view of a modified chip holding area of a toner cartridge with the forward retaining elements removed and with a replacement chip installed in accordance with the present invention; 
           [0010]      FIG. 3  shows a frontal view of the modified chip holding area and replacement chip of  FIG. 2  in accordance with the present invention; 
           [0011]      FIG. 4  shows a perspective view of the modified chip holding area, replacement chip and glue drops in accordance with the present invention; 
           [0012]      FIG. 5  shows a frontal view of the modified chip holding area, replacement chip and adhesive layer in accordance with the present invention; 
           [0013]      FIG. 6  shows a perspective view of modified chip holding area, replacement chip and adhesive with release liner in accordance with the present invention; 
           [0014]      FIG. 7  shows a perspective view of modified chip holding area, replacement chip and blocking element in accordance with the present invention; 
           [0015]      FIG. 8  shows a perspective view of a plug insert in accordance with the present invention; 
           [0016]      FIG. 9  shows a perspective view of the modified chip holding area, replacement chip and a plug insert installed in accordance with the present invention; 
           [0017]      FIG. 10  shows a perspective view of a locking flange in accordance with the present invention; 
           [0018]      FIG. 11  shows a perspective view of a locking flange attached to a replacement chip in accordance with the present invention; 
           [0019]      FIG. 11A  shows a perspective view of an alternate embodiment of a locking flange attached to a replacement chip in accordance with the present invention; and 
           [0020]      FIG. 12  shows a perspective view of the modified chip holding area, replacement chip and locking flange in accordance with the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    The following detailed description of preferred embodiments refers to the accompanying drawings which illustrate specific embodiments of the invention. In the discussion that follows, specific systems and techniques for repairing, manufacturing or remanufacturing a toner cartridge are disclosed. Other embodiments having different structures and operations for the repair, remanufacture and operation of other types of replaceable imaging components and for various types of imaging devices, such as laser printers, inkjet printers, copiers, facsimile machines and the like, do not depart from the scope of the present invention. 
         [0022]      FIGS. 1 and 1A  show, respectively, a perspective view and a frontal view of a portion of a prior art toner cartridge  100 . As understood by one of ordinary skill in the art, the toner cartridge  100  may include, among other components, a waste bin, a toner hopper, and an organic photo conductor (OPC) drum. The toner cartridge  100  also includes a chip holding structure  102  comprising a left upper flange  104 , a right upper flange  106 , a rear retaining member  108 , bottom supporting rails  110  and  112 , a left forward retaining element  114  extending from the left upper flange  104 , and a right forward retaining element  116  extending from the right upper flange  106  of the toner cartridge  100 . The chip holding structure  102  holds a chip  150  in a substantially fixed position. The chip  150  may include electrical contacts  152  on one side of a printed circuit board (PCB)  154  for engagement with a printer and circuitry  158  including a memory element on the opposing side. 
         [0023]    The left upper flange  104  and the right upper flange  106  hold the chip  150  from the top and the sides while the bottom supporting rails  110  and  112  support the bottom of the chip  150 . The rear retaining member  108  holds the chip  150  from the rear, and the left forward retaining element  114  and the right forward retaining element  116  hold the chip  150  from the front. As seen in  FIG. 1 , the left forward retaining element  114  and the right forward retaining element  116  are angled diagonally across a front edge of the chip  150 . 
         [0024]    As described above, during the process of remanufacturing the toner cartridge  100 , the chip  150  needs to be removed and replaced with a replacement chip. In order to remove the chip  150 , the forward retaining element  114  and the forward retaining element  116  should be removed. This removal may be accomplished through the use of a cutting tool, such as knife, for example. As the chip  150  is not secured directly to the toner cartridge  100 , the chip  150  may then be removed. A replacement chip may then be inserted into the area previously occupied by the chip  150 .  FIGS. 2 and 3  show, respectively, a perspective view and a frontal view of a modified chip holding structure  202  of a toner cartridge  100  with the forward retaining elements  114  and  116  removed and with a replacement chip  250  installed in accordance with the present invention. The replacement chip  250  may comprise contacts  252  on one side of a PCB  254  communicatively connected to a circuitry unit  258 , such as a microcontroller, memory device or application specific integrated circuit (ASIC), for example. With the forward retaining elements  114  and  116  removed, the replacement chip  250  is not be secured to the toner cartridge  100 . The present invention provides techniques for solving this problem and attaching a replacement chip  250  to the modified chip holding structure  202  of the toner cartridge  100 . 
         [0025]      FIG. 4  shows a perspective view of the modified chip holding structure  202 , replacement chip  250  and adhesive drops  400  in accordance with the present invention. In one aspect of the present invention, after the replacement chip  250  has been installed in the modified chip holding structure, one or more adhesive drops  400  may be placed on the toner cartridge  100  and the replacement chip  250  to secure the replacement chip  250  in place. The adhesive drops  400  may suitably comprise glue or other adhesive material. In a preferred embodiment, the adhesive drops are placed along an edge of the PCB  254 , as shown in  FIG. 4 , in the area where the left forward retaining element  114  and the right forward retaining element were removed. 
         [0026]      FIG. 5  shows a frontal view of the modified chip holding structure  202 , replacement chip  250  and adhesive layer  500  in accordance with another aspect of the present invention. The adhesive layer  500  may comprise a double-sided adhesive, manufactured glue dot, or the like which is attached to the underside of the replacement chip  250  prior to installation of the replacement chip  250 . Alternatively, the adhesive layer  500  may be attached to the modified chip holding structure  202  prior to installation of the replacement chip  250 . After the replacement chip  250  is installed in the modified chip holding structure  202 , the adhesive layer  500  attaches the replacement chip  250  to the toner cartridge  100 . When the replacement chip  250  is installed, a small amount of space should be maintained between the adhesive layer  500  and the toner cartridge (or, alternatively, between the adhesive layer  500  and the replacement chip  250 ) to ensure there is no binding before the replacement chip  250  is fully inserted. Alternatively, the adhesive layer  500 , which may comprise a glue dot or glue, may be inserted between the replacement chip  250  and the toner cartridge after the replacement chip  250  has been installed. 
         [0027]    Alternatively, as shown in  FIG. 6 , a pull film or release liner  600  may be attached to the adhesive layer  500 .  FIG. 6  shows a perspective view of the modified chip holding structure  202 , replacement chip  250  and adhesive with release liner  600  in accordance with the present invention. The release liner  600  is attached to and covers the adhesive layer  500 , and extends outward from the replacement chip  250 . When the replacement chip  250  is inserted into the modified chip holding structure  202 , the release liner  600  protects the adhesive, acting as a mechanical buffer between the adhesive layer  500  and the toner cartridge  100 . After installation, the release liner  600  is pulled away, exposing the adhesive layer  500  to the toner cartridge  100 . Light pressure on the front face of the replacement chip  250  may be needed to fully activate the adhesive bond between the replacement chip  250  and the toner cartridge  100 . 
         [0028]      FIG. 7  shows a perspective view of the modified chip holding structure  202 , replacement chip  250  and blocking element  700  in accordance with another aspect of the present invention. The blocking element  700  attaches to the toner cartridge  100  and secures the replacement chip  250  in place in the modified chip holding structure  202 . The blocking element  700  may suitably comprise a material  702 , such as high impact polystyrene (HIPS), with an adhesive layer  704  securing the blocking element  700  in place. Alternatively, the blocking element  700  may comprise other securing techniques, such as a clip or a fastener, for example. 
         [0029]    In another aspect of the present invention, a plug insert  800  may hold the replacement chip  250  in place.  FIG. 8  shows the plug insert  800  in accordance with the present invention. The plug insert  800  is inserted into the front of the modified chip holding structure  202  after the replacement chip  250  is installed and locks into place, as shown in  FIG. 9 . A variety of techniques may be used to lock the plug insert  800  into place including, for example, glue, snap mechanisms, or press fit features such as crush ribs. The plug insert  800  may include a narrowed section  802  which slides under the replacement chip  250 . In an alternate embodiment the plug insert  800  may include an adhesive layer  804  holding the plug insert  800  in place. The plug insert  800  may suitably comprise molded plastic. 
         [0030]    In another aspect of the present invention, a locking flange  1000  may hold the replacement chip  250  in place.  FIG. 10  shows the locking flange  1000  in accordance with the present invention. The locking flange  1000  may comprise a base  1002 , a chip adhesive layer  1004  on one side of the base  1002  and a locking adhesive layer  1006  on the opposing side of the base  1002 . The base  1002  may suitably comprise HIPS, plastic film, and the like, for example. As shown in  FIG. 11 , the chip adhesive layer  1004  attaches the locking flange  1000  to the underside of the replacement chip  250 . After the replacement chip  250  is installed in the modified chip holding structure  202 , the end of the locking flange  1000  extending outward from the replacement chip  250  is folded down and attached to the toner cartridge  100  by the adhesive layer  1006 . See  FIG. 12 . To remove the replacement chip  250  during future remanufacturing, the end of the locking flange  1000  is lifted off the toner cartridge  100  and pulled, thereby removing the replacement chip  250 . In an alternate embodiment, the locking adhesive layer  1006  may be located on the same side of the base  1002  as the chip adhesive layer  1004 , as shown in  FIG. 11A , with the end of the locking flange  1000  extending outward from the replacement chip  250  being folded along line  1010 , for example, to orient the locking adhesive layer for attachment to the toner cartridge  100 . 
         [0031]    Although specific embodiments have been illustrated and described herein, those of ordinary skill in the art appreciate that any arrangement that is calculated to achieve the same purpose may be substituted for the specific embodiments shown and that the invention has other applications in other environments. This application is intended to cover any adaptations or variations of the present invention. The following claims are in no way intended to limit the scope of the invention to the specific embodiments described herein.