Abstract:
A device for manufacturing a printer cartridge, the printer cartridge having a doctor blade and a developer roller, the doctor blade being configured to regulate the amount of toner delivered to the developer roller, the device comprising: (a) first surface, the first surface lying on a first plane; and (b) a second surface positioned opposite the first surface, the second surface lying on a second plane, the first and the second plane being parallel to each other, the second surface comprising a flat portion, the flat portion being configured to contact a portion of the doctor blade, wherein when the flat portion contacts the doctor blade portion, the device applies pressure to the doctor blade portion.

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
     This application is a continuation application of U.S. application Ser. No. 11/700,605 filed on Jan. 31, 2007, now U.S. Pat. No. 7,505,708. 
    
    
     FIELD OF INVENTION 
     The present invention relates to electrophotography, particularly methods and apparatus for manufacturing or remanufacturing toner cartridges. 
     BACKGROUND 
     Used printer cartridges of fax machines, copiers, inkjet printers, and laser printers are often remanufactured. The remanufacturing of printer cartridges may include cleaning, repairing damaged parts, replacing worn parts, and adding toner. The parts of printer cartridges typically include a toner hopper, a waste hopper, primary charge roller (PCR), a developer roller, and a drum. 
     Generally, printers embed toner on paper by relying on electrical charges occurring within the printer cartridges. The toner is typically stored in the toner hopper and carries a negative charge. The drum is typically given a charge by the 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 toner may be carried to the drum by the developer roller (sometimes referred to as a “mag roller”), which may also preserve the uniform electrical charge of the toner. A doctor blade (sometimes referred to as a “doctor bar”) may be provided and positioned proximate to the developer roller with a predetermined distance. The doctor blade ensures that the right amount of toner sticks to the developer roller. If there is an excess amount of toner on the developer roller, the doctor blade scrapes off the excess amount. The developer roller then transfers the toner to the drum. 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. 
     The doctor blade and the developer roller are usually detached from printer cartridge during remanufacturing for cleaning. After cleaning, the doctor blade and the developer roller are reassembled together usually by hand and a screw driver. An assembler usually positions the doctor blade above the developer roller. The assembler would press on one side of the doctor blade then screw the same side of the doctor blade to the cartridge. The assembler would then execute the same steps on the remaining side. 
     The applicant has observed that this conventional method of assembly may not provide a uniform distance between the doctor blade and the developer roller from one side of the doctor blade to the other. As a result, the print quality may be affected, as the toner level on the developer roller is not effectively regulated by the doctor blade. One side of the roller may produce darker image than the other, or vice-versa. Methods and apparatus for effectively assembling the doctor blade proximate to the developer roller are desired and are addressed by the present invention. 
     Next, the toner hopper is typically refilled with toner during remanufacturing. Toner is typically introduced into the toner hopper either by drilling a hole, refilling the toner, then covering the hole, or by filling the toner hopper with toner through an existing toner hopper recess. Typically, these steps are executed by hand and a drill. At least one problem with the conventional technique is that the toner hopper is not secured throughout the process. The toner hopper may move during the drilling or the refilling steps, which may add to the time it takes to complete the refilling process. This additional time is undesirable in a high volume manufacturing environment. Moreover, the conventional technique may not produce uniform sized hopper holes for introducing the toner. Some hopper holes may be too small for refilling the toner, and some hopper holes may be too big to cover after refilling. Methods and apparatus for effectively refilling the cartridge with toner are desired and are addressed by the present invention. 
     BRIEF DESCRIPTION 
     A device for manufacturing a printer cartridge, the printer cartridge having a doctor blade and a developer roller, the doctor blade being configured to regulate the amount of toner delivered to the developer roller, the device comprising: (a) first surface, the first surface lying on a first plane; and (b) a second surface positioned opposite the first surface, the second surface lying on a second plane, the first and the second plane being parallel to each other, the second surface comprising a flat portion, the flat portion being configured to contact a portion of the doctor blade, wherein when the flat portion contacts the doctor blade portion, the device applies pressure to the doctor blade portion. 
     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. 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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is substantially a front elevational view of an embodiment of the cartridge assembly device of the present invention. 
         FIG. 2  is substantially a side view of the cartridge assembly device shown in  FIG. 1  with a clamp at an angled position relative to the base. 
         FIG. 3  is substantially a side view of the cartridge assembly device shown in  FIG. 1  with the clamp at a perpendicular position relative to the base. 
         FIG. 4  is substantially a perspective view of the cartridge assembly device shown in  FIG. 1  with a drill to cut a hole into the cartridge. 
         FIG. 5  is substantially a side view of the cartridge on the cartridge assembly device shown in  FIG. 1  and the cartridge being refilled with toner. 
         FIG. 6  is substantially a front elevational view of the cartridge refilled with toner in  FIG. 5  and with the refill hole being covered. 
         FIG. 7  is substantially a side partial view of the cartridge assembly device shown in  FIG. 1  with the doctor blade being positioned for attachment to the printer cartridge. 
         FIG. 8  is substantially a perspective view of the cartridge assembly device shown in  FIG. 1  with the doctor blade being attached to the printer cartridge. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     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. 
     The term “developer roller” is commonly used in the cartridge manufacturing industry to refer to typically cylindrical material in a printer cartridge that attracts toner usually by static charge and is typically positioned in between a doctor blade and a drum. In some cartridges, the developer roller may be magnetized and may be referred to as a “mag roller.” When the cartridge is in operation, the developer roller typically rolls along with the drum to provide toner to the drum thereby allowing the drum to produce a print pattern to a paper that is being rolled around the drum. The term “doctor blade” is another commonly used term in the cartridge manufacturing industry, which refers to an elongated material that usually includes an elongated rod with an elongated blade attached to the elongated rod. The elongated rod is usually made of metal, and the elongated blade is typically made of plastic. The blade may be positioned at an angle from the rod and may be positioned next to the developer roller. When the cartridge is in operation, the doctor blade is typically stationary while the developer roller rolls next to the blade. Not all toner may be absorbed by the developer roller. The toner that is not absorbed by the developer roller typically accumulates around the developer roller. Since the doctor blade and the developer roller are separated by a relatively small predetermined space, the blade controls the thickness of the toner that adheres to the developer roller by scraping off toner that is not absorbed by the developer roller. 
     The present invention comprises a cartridge assembly device and related methods of use. Referring to  FIG. 1 , the cartridge assembly device  20  may include a fixture  22 , a clamp  24 , and a doctor blade press  26 . The fixture  22  may serve as a device for supporting work during manufacturing or remanufacturing. The doctor blade press  26  may serve as a pressure material that applies pressure to the doctor blade (not shown in  FIG. 1 ) to effectively position the doctor blade next to the developer or mag roller during cartridge assembly such that the doctor blade may effectively regulate the toner being delivered to the developer or mag roller and consequently enhance the resulting print quality of the printer cartridge. The doctor blade press  26  may also serve as a template for creating a toner refill hole, which is described further below. The clamp  24  may serve to enhance the functions of the doctor blade press  26  and the fixture  22 . 
     The fixture  22  preferably includes a board material  28 , which may serve as a base for the cartridge assembly device. The board material  28  may include four sides  30   a - d , which form a plane. The board material  28  may further include a plurality of projections  32   a - d  configured to hold a toner hopper such that when the toner hopper is laid on the board material, each of the plurality of projections  32   a - d  cooperate to prevent the toner hopper from moving forward, backward, or side-to-side relative to the board material  28 . It is noted the board material  28  may also be configured to hold an entire cartridge or cartridge portions other than the toner hopper. It is further noted that, terms relating to spatial orientation, such as “forward,” “backward,” and “side-to-side” are used herein for ease and clarity of description only. The invention is not limited by these spatial orientations and may be practiced without observing the descriptions that use these spatial orientations. 
     Board material  28  may include side projections  32   a  and  32   b  to restrict the movement of a toner hopper laid on the board material  28  by providing side walls that confine the toner hopper there between. The side projections  32   a  and  32   b  may be positioned parallel to the board sides  30   c  and  30   d , respectively, and may be offset relative to each other. Side projections  32   a  and  32   b  may be configured to cause cartridge end caps to abut to them. The offset may help prevent the toner hopper from moving forward and backward relative to the board material  28  in the position shown in  FIG. 1 . 
     Board material  28  may also include a pair of parallel elongate projections  32   c  and  32   d  designed to cause a bottom portion of a toner hopper to abut to the projections  32   c  and  32   d  so that the toner hopper is prevented from moving forward and backward relative to the board material  28  in the position shown in  FIG. 1 . The pair of parallel elongate projections  32   c  and  32   d  may be positioned perpendicular to sides  30   c  and  30   d  and parallel to sides  30   a  and  30   b . The sizes, shapes, orientations, and positions of the projections may vary depending on the design of the toner hopper, cartridge, or cartridge portion intended to be laid onto the board material  28 . In certain embodiments, the board material may have indentations or holes (not shown) in lieu of projections, which may define walls that are configured hold the toner hopper, cartridge, or cartridge portion laid onto the board material. It can be realized that the fixture  22  of the present invention affixes the toner hopper, cartridge, or cartridge portion to a substantially steady position, which may be ideal for performing manufacturing or remanufacturing work on each of them, such as refilling the toner hopper and installing toner hopper components. 
     A clamp  24  may be mounted to a clamp platform  34  of the board material  28 . Clamp  24  may be fastened to the clamp platform  34  using fasteners known in the art. The doctor blade press  26  may be attached to the clamp  24 . It can be appreciated that the clamp  24  may move the doctor blade press  26  up and down relative to the board material  28 . It can further be appreciated that the clamp  24  may provide a downward pressure to the doctor blade press  26 , which may be beneficial in securing the doctor blade to the cartridge and positioning the doctor blade next to the developer, as described further below. 
     Referring now to  FIG. 2 , clamp  24  may be a “hold down action” clamp from De-Sta-Co of Birmingham, Mich. The clamp  24  may include a handle  36 , a clamp base  38 , a first clamp arm  40 , and a second clamp arm  42 . One end of the first clamp arm  40  is preferably attached at the top of the doctor blade press  26 , and the other end is preferably attached to the second clamp arm  42 . The second clamp arm  42  may also be attached to the handle  36 . The handle  36  is preferably attached to the clamp base  38 . 
     The handle  36  may be moved from a position substantially perpendicular to the board material  28  to an angled position that is between approximately 90 degrees to 140 degrees from the center of the board material  28 . When the handle  36  is moved from the perpendicular position to the angled position, the handle  36  preferably pivots around a first base pivot  44 , which is attached to the clamp base  38 . One end of the second clamp arm  42  preferably pivots around the handle pivot  46 . The other end of the second clamp arm  42  preferably pivots around the arm pivot  48 . The handle  36  and the second clamp arm  42  pull the first clamp arm  40  upward relative to the base material  28 . When the first clamp arm  40  moves upward relative to the base material, the first clamp arm  40  preferably pivots around the second base pivot  50  ( FIG. 3 ) that is attached to the clamp base  38 . When the handle is at the angled position, the doctor blade press  26  is preferably not in contact with the toner hopper  54 , cartridge, or cartridge portion positioned on the board material  28  ( FIG. 2 ). 
     Referring now to  FIG. 3 , when the handle  36  is moved to the perpendicular position, the doctor blade press  26  preferably lays on top of the toner hopper. Thus, the toner hopper  54  is substantially prevented from moving vertically by the doctor blade press  26  and base material  28 . The cartridge is also substantially prevented from moving horizontally by the projections  32   a - d  of the base material  28 . It can be realized that the cartridge  54  may now be in a substantially steady position that is ideal for drilling a hole into the toner hopper so that the toner hopper may be refilled with toner. 
     With continued reference to  FIG. 3 , the doctor blade press  26  may serve as a refill hole template. Specifically, the doctor blade press  26  preferably includes a bottom surface that is configured to lay substantially flush on the toner hopper. The doctor blade press preferably defines a recess  56  of a predetermined size, which may be used as a guide for creating a refill hole on the toner hopper  54 . 
     Referring now to  FIG. 4 , a circular saw may be attached to a drill  58  and introduced into the recess  56 . The drill may be activated to allow the circular saw to create a hole on the toner hopper of the cartridge  54 . Referring now to  FIG. 5 , after the hole is created, the cartridge  54  may be refilled with toner from a toner bottle  60  with toner dispenser  62 . The dispenser  62  may positioned next to the refill hole  64 , and toner may be dispensed into the refill hole  64 . After the desired amount of toner has been added into the toner hopper, the refill hole  64  may be sealed with a cover  66  ( FIG. 6 ). The cover  66  may have an adhesive backing, which may adhere to the toner hopper when placed in contact with a toner hopper surface. 
     Referring now to  FIG. 7 , the doctor blade press  26  may be positioned on top of the elongated support rod  58  of the doctor blade to act as a source of pressure for the doctor blade. It is desirable to apply a substantially uniform pressure on the doctor blade when it is being attached to the cartridge so that the distance between the blade  52  and developer roller  62  is kept as level as possible throughout the lengths of the doctor blade and the developer roller. If said distance is kept as level as possible, the blade  52  can regulate the toner amount on the developer roller uniformly across the length of the developer roller. Referring now to  FIG. 8 , when the handle  36  is moved to the perpendicular position, the clamp  24  may provide additional pressure to the doctor blade press  26  that may be applied to the doctor blade. The clamp  24  may be locked in the perpendicular position, and the doctor blade  52  may be screwed onto the cartridge, such as at position “A” shown in  FIG. 7 . 
     It can now be realized that the present invention provides a device that may effectively hold a cartridge portion or an entire cartridge during assembly, toner refill, remanufacture, refurbishment, repair, or maintenance. As a result, a cartridge assembler may be able to work efficiently and quickly. The present invention may also provide devices and methods that effectively position the doctor blade proximate to the developer or mag roller during assembly, which may be beneficial in allowing the doctor blade to regulate the toner amount on the developer or mag roller. As a result, the print cartridge assembled, remanufactured, or maintained with the devices and methods of the present invention may provide high print quality. Finally, the present invention provides a template for creating a refill hole on a toner hopper, which may allow for an efficient toner refill procedure. 
     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, the shape of the base fixture may vary. Various clamp designs may be adopted. The doctor blade press  26  may be made or used with or without the clamp  24  and may still provide some of the advantages of the present invention. For instance, the doctor blade press  26  may be placed on top of the doctor blade by itself. Hand pressure may be applied to the doctor blade pressure while attaching the doctor blade to the cartridge. It can be appreciated that with this embodiment, the doctor blade press  26  is still able to apply a substantially uniform pressure on the doctor blade when it is being attached to the cartridge so that the distance between the blade  52  and developer roller  62  is kept as level as possible throughout the lengths of the doctor blade and the developer roller. The devices and methods of the present invention may be used in manufacturing or remanufacturing toner cartridges. 
     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.