Abstract:
A reinforcing clip for use in the toner cartridge remanufacturing industry is disclosed. The reinforcing clip secures a magnetic roller section as it is positioned on a toner hoper reservoir of a toner cartridge. The toner hopper reservoir has a limited amount of space available to mount such a clip. The present invention provides a securing force which is about perpendicular to the fastening force of the reinforcing clip&#39;s two securing legs.

Description:
FIELD OF INVENTION 
       [0001]    The present invention relates to remanufacturing of imaging process cartridges, such as printer toner cartridges, and more particularly to reinforcing rail clip for use in adding rigidity and stability to a seam in a remanufactured image process cartridge. 
       BACKGROUND 
       [0002]    Printer cartridges are typically designed to provide the consumer a certain number of print copies before the toner or ink is exhausted. The total number of prints varies depending on the type, quality and density of the print provided by the printer. After all of the toner or ink is spent, the cartridges are either thrown away or recycled. 
         [0003]    An emerging industry has developed that deals with the recycling of printer cartridges. Typically, the OEM (Original Equipment Manufactured) cartridge is recycled by a cartridge remanufacturer, who receives spent printer cartridges and refurbishes them. The toner cartridge remanufacturing process typically entails disassembling, cleaning, refurbishing and reassembling the cartridge. The last step of the refurbishment process typically includes refilling the cartridge with toner and repackaging the cartridge. 
         [0004]    A typical OEM toner cartridge comprises an assembled plastic housing. The material of the housing may be molded plastic or other plastic composite. Where the various parts of the cartridge join together, a seam may exist. In some laser toner cartridges, the seam may be held together by ultrasonic welding. On other types of toner cartridges glue or other adhesive may be used to hold the seam in place. 
         [0005]    Once the seam or seams have been broken and the various parts of the toner cartridge separated, the worn or broken parts may be replaced. As the cartridge is reassembled, a clip may be used to hold the pieces in place instead of ultrasonically welding the seam of gluing. The use of a clip, such as those described in U.S. Pat. No 6,240,605, issued to Stevens et al., assigned to the present assignee, and its contents are incorporated herein, may be used in order to facilitate the remanufacturing of a remanufactured cartridge. However, those clips as described in Stevens et al. require two opposing surfaces to create a seam. The two ends of the clip provide a securing and stabilizing force against the seam by providing pulling the two sections towards each other. 
         [0006]    However, in some newer toner cartridges, the seam may be formed by two orthogonally joining surfaces. In this case, the prior art clips do not have enough surface for its legs to attach to and still provide enough securing and stabilizing force to hold the reassembled cartridge together. The present invention may be used to secure a seam in a toner cartridge where the securing and stabilizing force is applied by an elongated arm that extends away from the one of the legs of a reinforcing clip. 
       SUMMARY 
       [0007]    A reinforcing clip for use in securing a seam in a remanufactured image process cartridge having a toner hopper reservoir section and a magnetic roller section, said seam formed from the joining of said toner hopper reservoir section and said magnetic roller section, the clip comprising a first securing edge connected to a second securing edge by a connecting member, said clip attaching to a projection along said seam, said reinforcing clip further comprising an elongated arm attached to said second end, said elongated arm securing said magnetic roller section against said toner hopper reservoir. 
         [0008]    A remanufactured image process cartridge comprising a toner hopper reservoir attached to a magnetic roller section, wherein an orthogonal seam is formed from the joining of said toner hopper reservoir with said magnetic roller section, said magnetic roller section secured to said toner hopper reservoir by a reinforcing clip, said clip having a first end connected by a connecting member to a second end and an elongated arm protruding from said second end, said protruding arm exerting a force on said magnetic roller section against said toner hopper reservoir. 
         [0009]    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 
         [0010]      FIG. 1  shows a view of a fully assembled HP11A toner cartridge for use in an HP2410/2420/2430 family of printers. 
           [0011]      FIG. 2  shows an exploded view of a toner hopper assembly of the HP11A laser toner cartridge with the waste bin assembly removed. 
           [0012]      FIG. 3A  shows an end view of a split rail clip in accordance with one aspect of the present invention. 
           [0013]      FIG. 3B  shows a side view of the split rail clip of  FIG. 3A . 
           [0014]      FIG. 3C  shows a side perspective view of the split rail clip of  FIG. 3A . 
           [0015]      FIG. 4  shows an end view of another split rail clip according to another embodiment of the present invention. 
           [0016]      FIG. 5  displays an end view of yet another split rail clip according to another embodiment of the present invention. 
           [0017]      FIG. 6  shows an end view of yet another split rail clip according to another embodiment of the present invention. 
           [0018]      FIG. 7  displays an end view of yet another split rail clip according to another embodiment of the present invention. 
           [0019]      FIG. 8  shows a cutaway view of a seam created by the joining of a toner hopper reservoir and a magnetic roller section of the cartridge of  FIG. 1 . 
           [0020]      FIG. 9  shows the rail clip of  FIGS. 3A-C  installed on the seam of  FIG. 8 . 
       
    
    
     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 an imaging cartridge, such as a toner cartridge are used as examples. 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]    In the toner cartridge refurbishment industry, the used toner cartridges are collected and serviced by toner cartridge remanufacturers. The first step in the refurbishment process is the disassembling of the spent cartridges. Next, the internal components are separated. Non-functioning components are replaced, and the remaining components, as well as the body of the device undergo a cleaning process. In the final step the device is reassembled and new toner is added to the toner cartridge. The refurbished device is then packaged and distributed to the consumer. 
         [0023]    Typically the OEM uses ultrasonic welding to hold sections of the cartridge together. These welds are broken when the cartridge is disassembled by the remanufacturer. Those skilled in the art appreciate that ultrasonic welding may be utilized on plastic or plastic composite materials. No other hardware is required to hold the sections of the cartridge in place after the ultrasonic welds are done. 
         [0024]    During the disassembly of a toner cartridge, the ultrasonic welds are broken in order to separate the sections of the toner cartridge. The remanufacturer may use some type of sharp instrument such as a sharp blade or box cutter to sever the weld. Cutting the weld may be more time consuming than prying the sections apart with brute force. Some remanufacturers may decide that it is easier to use a screw driver, chisel or other type of instrument to pry the sections apart. 
         [0025]    After the cartridge has been completely disassembled, and the worn or used components identified and replaced, the toner cartridge is reassembled. During the reassembly of the cartridge, the remanufacturer may choose not to re-weld the sections together. In order to ultrasonically weld the sections, the remanufacturer may have to invest in expensive welding equipment that maybe too cost prohibitive. Additionally, after the ultrasonic weld is broken, material at the seam may be compromised enough that there is not be enough material remaining to re-weld. 
         [0026]    One alternative that has been developed for securing the sections of a toner cartridge are clips. Clips are an excellent alternative to ultrasonic welding. Using a clip to hold the various sections together allows the remanufacturer to easily disassemble the cartridge during a later refurbishment. No welding equipment is necessary when utilizing a clip. However, previous clips used in the toner remanufacturing industry are designed to provide a securing and stabilizing force in diametrically opposed directions. The seams on these types of cartridges are formed from the mating of two parallel surfaces. The legs of the prior art clip fasten to these parallel surfaces and push them together. However in some newer cartridges, the two parallel surfaces that form the seam may not have enough area to attach these prior art clips. The present invention is designed to provide a securing and stabilizing force necessary to keep this type of seam sealed after the remanufacturing process. 
         [0027]    The present invention is more clearly understood in reference to the cartridge  100  displayed in  FIG. 1 . The cartridge  100  may be used in an HP2410/2420/2430 family of printers. Cartridge  100  has three main sections, the toner hopper reservoir  110 , the magnetic roller section  120  and the waste bin  130 . In the OEM cartridge, the toner hopper reservoir  110  and the magnetic roller section  120  may be held together by ultrasonic welds. When the cartridge  100  is disassembled, the ultrasonic weld is broken and the parts are separated. 
         [0028]      FIG. 2  displays an exploded view of cartridge  100  with the waste bin assembly  130  already removed. Toner cartridge  100  does not have any opening in the toner hopper reservoir  110  to refill toner, so the remanufacturer must create such an opening in order to install new toner. The opening is sealed by placing a toner hopper cap  202  over the opening. 
         [0029]    When cartridge  100  is reassembled, a seal  206  is first placed over the toner hopper opening  216 . The seal  206  has a removable plastic portion attached to a pull tab  204  that covers the toner hopper opening  216 . The seal keeps toner confined in the toner hopper reservoir  110  during shipment of the cartridge  100 . Prior to installing the cartridge  100  in a printer, the removable plastic portion is removed by pulling the pull tab  204 . Removing the removable portion allows toner to flow from the toner hopper reservoir  110  into the magnetic roller section  120 . 
         [0030]    Once the seal  206  is place on the toner hopper reservoir  110 , the magnetic roller section  120  is then placed on top of the toner hopper reservoir  110 . The present invention is used to secure the magnetic roller section  120  against the seal  206  and the toner hopper reservoir  110 . Next, a doctor blade  214  and magnetic roller wiper tabs  222  are secured on top of the magnetic roller section  120  with two securing screws (not shown). The magnetic roller assembly consisting of the long magnetic roller bushing  218 , magnetic roller  232 , short magnetic roller bushing  224 , stabilizer bearing  226 , stabilizer  228  and magnetic roller drive gear  230  are assembled and placed in the magnetic roller section  120 . 
         [0031]    Next, a drive side end plate  208  and a contact side end plate  212  are placed on the sides of the magnetic roller section  120  and are secured into place with end plate screws (not shown). Once the end plates  208 ,  212  are secured into place, a drum shutter  238  is then attached. Connected to the drum shutter is a drum shutter tension spring  234  and a drum shutter actuator arm  236 . The movement of the drum shutter actuator arm  236  causes the drum shutter to open and expose the OPC (Organic Photo Conductor) drum (not shown). 
         [0032]      FIG. 8  displays a cutaway view of toner cartridge  100  at the juncture of the toner hopper reservoir  110  and magnetic roller section  120  at the top section of the toner hopper opening  216 . Mounted on top of magnetic roller section  120  is the doctor blade  214 . As shown in  FIG. 8 , a seam  240  is formed at the location where the top of the toner hopper reservoir  110  is joined with the top of the magnetic roller section  120 . A flange  122  extends away from the magnetic roller section  120  towards a ledge  115  of toner hoper reservoir  110 . In between the ledge  115  and the main body of the magnetic roller section  120  is a gap  124 . The gap  124  of cartridge  100  is about 0.4″ (10.2 mm). As shown in  FIG. 8 , the seal  206  is compressed in the seam  240 . The seam  240  extends around the perimeter of the toner hopper opening  216 . 
         [0033]    The prior art clips are not usable to stabilize and secure this type of seam due to the lack of a sufficient securing surface. Prior art clips apply a securing force in opposing directions, typically a downward direction  802 , and an upward direction  804 . As illustrated in  FIGS. 8 and 9 , all forces exerted by the prior art clips as well as the present invention are represented with dashed lines. In order to use a prior art clip, one leg of the clip would need to be small enough to fit into the gap  124  and be placed against the flange  122 . The other leg of such clip would have to be placed at a location on the toner hopper reservoir  110  to provide an upward force  804  necessary to secure the seam  240 . This type of clip would have to be molded around the ledge  115  as well as the rest of the contours of the toner hopper reservoir  110 . The present invention provides a securing force for a cartridge  100  of this type. 
         [0034]    A reinforcing clip  300  in accordance with one aspect of the present invention is displayed in  FIGS. 3A-C . The reinforcing clip  300  has a first securing leg  320  connected to a second securing leg  340  by a connecting member  310 . Opposite the connecting member  310  is an opening  335  which is in between the first securing leg  320  and the second securing leg  340 . Typically the opening  335  is slightly smaller than the thickness of ledge  115  of the toner hopper reservoir  110 . Attached to second securing leg  340  is an elongated arm  330  having a length of l 1  which extends away from the second securing leg  340  and is roughly parallel with connecting member  310 . The length l 1  of the elongated arm  330  may vary with the dimension of gap  124 . In the embodiment of  FIGS. 3A-C , the length l 1  is about 0.12″ (3.0 mm). 
         [0035]    Located on the second securing leg is a securing protrusion  350 . In the preferred embodiment, the securing protrusion  350  is a barb that is triangularly shaped. As shown in  FIG. 3B , the securing protrusion  350  is formed from a cut made in the wall of the second securing leg  340  and is bent inwards toward the first securing leg  320 . Instead of a pointed barb, the securing protrusion  350  may have a smooth surface. Alternatively, the securing protrusion  350  may have multiple points. 
         [0036]    The first securing leg extends away from the connecting member  310  by a height l 1  of about 0.222″ (5.64 mm). The end of the elongated arm protrudes a height l 2  from the connecting member  310  which is slightly longer than l 1 . In the embodiment of  FIGS. 3A-C , height l 2  is about 0.225″ (5.72 mm). As shown in  FIG. 3B , reinforcing clip  300  has a length l 2 . In a preferred embodiment, the length l 2  is about 1.25″ (31.75 mm). The number of reinforcing protrusions may depend on the length l 2  of the reinforcing clip  300 . In the preferred embodiment, two securing protrusions  350  are created. The greater the length l 2  the more securing protrusions  350  may be required. 
         [0037]    The reinforcing clip  300  is substantially rigid, thus ensuring that the reinforcing clip  300  is securely attached while providing enough clamping force to securely fasten the magnetic roller section  120  to the toner hopper reservoir  110 . The reinforcing clip may be formed of any type of material that provides such rigidity such as steel, aluminum, plastic or plastic composite. The rigidity of the reinforcing clip  300  causes the elongated arm  330  to act like a spring when attached. 
         [0038]      FIG. 9  displays the cutaway view of  FIG. 8  with a reinforcing clip  300  attached to ledge  115  of toner hopper reservoir  110 . When attached, the securing protrusion  350  of the reinforcing clip  300  extends into the ledge  115 . Additionally, the first securing leg  320  and the second securing leg  340  exert a securing force  806  against the ledge  115 . The combination of the securing force  806  in conjunction with the force exerted by the securing protrusion  350  provides additional stability for the reinforcing clip  300  as well as additional rigidity to the elongated arm  330 . Unlike previous clips, reinforcing clip  300  provides only a downward force  802  against the seam  240 . The downward force exerted by the elongated arm  330  is perpendicular to the securing force used to hold the reinforcing clip  300  in place on the ledge  115  of the toner hopper reservoir  110 . 
         [0039]      FIG. 4  displays an alternative embodiment of a reinforcing clip  400  in accordance with another aspect of the present invention. The reinforcing clip  400  has a securing protrusion  350  located on the first securing leg  320 . The reinforcing clip  500  of  FIG. 5  has securing protrusions  350  located on both the first securing leg  320  and the second securing leg  340 . A reinforcing clip  600  with no securing protrusions  350  is displayed in  FIG. 6 . A rectangular shaped reinforcing clip  700  is shown in  FIG. 7 . All of the aforementioned reinforcing clips may be made out of the same materials and have roughly the same dimensions as previously described. 
         [0040]    When reassembling the toner hopper reservoir  110  with the magnetic roller section  120 , several clips may be used. With the preferred embodiment as described herein, three reinforcing clips  300  are recommended to be installed on the ledge  115  of the toner hopper reservoir  110 . The preferred locations  260  as shown in  FIG. 2  are in the top corners as well as in the center of the top of the toner hopper reservoir  110 . In addition to the three reinforcing clips  300  installed at locations  260 , three prior art clips may be used at locations  265 . The prior art clips may be used at these locations  265  since there is enough securing surface. These locations  260  and  265  ensure that the seam  240  has sufficient securing force to prevent any toner from leaking out of the toner hopper reservoir  110  either during shipment or during normal operation. 
         [0041]    Although specific embodiments have been illustrated and described herein, those of ordinary skill in the art appreciate that any arrangement, which 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.