Abstract:
Techniques are provided for modifying a printer cartridge intended for installation in one type of printer to be installed in another type of printer or a plurality of printers. In one aspect, a method of modifying a toner cartridge may include modifying one or more end portion of the toner cartridge. In another aspect, a method of modifying a toner cartridge may include adding a patch on the converted cartridge.

Description:
FIELD OF INVENTION 
       [0001]    The present invention relates to remanufacturing and modifying imaging process cartridges, such as printer toner cartridges, and more particularly to techniques for modifying an imaging process cartridge intended to operate in one type or model of imaging device, such as a printer, to operate in additional types or models of imaging devices. 
       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 cartridge is recycled by a cartridge remanufacturer, who receives spent printer cartridges and refurbishes them. The refurbishment process entails replacing the worn or nonfunctioning parts, refilling the cartridge with either toner or ink, and distributing the refurbished cartridges into the marketplace. 
         [0004]    Toner cartridges are typically designed to fit into one type of laser printer or family of laser printers. For example, the same toner cartridge may be used in an HP4200 or HP4300 monochrome laser printer. As new printer models are introduced, the printer manufacturer may decide to alter the physical characteristics of the printer cartridge. In some cases the alteration may be an entirely new shape or the printer manufacturer may only change a minor detail such as an indentation or a protrusion on the cartridge. 
         [0005]    A typical toner cartridge comprises an assembled plastic housing. The material of the housing may be molded plastic or other plastic composite. During the remanufacturing of the cartridge, the cartridge is disassembled, cleaned, refurbished and reassembled. The last step of the refurbishment process typically includes refilling the cartridge with toner and repackaging of the cartridge. As part of the refurbishment process, the toner cartridges may be modified in order to remove any restriction regarding usage. 
         [0006]    The present invention converts a printer imaging cartridge such as a laser toner cartridge for use in one type of printer to be usable in another type of printer by removing a protrusion and a horizontal edge from an end portion of the toner cartridge. In another embodiment of the present invention, a rib is removed from an end portion of another type of toner cartridge, allowing the modified toner cartridge to be used in another type of printer. 
       SUMMARY 
       [0007]    A method of modifying an imaging process cartridge, the imaging process cartridge installable in a first imaging device and not installable in a second imaging device, the method comprising, providing the imaging process cartridge, said imaging process cartridge comprising a contact side end portion, said contact side end portion further comprising a lower vertical surface extending from a first end to a mid point of said end portion, wherein a protrusion is mounted on said lower vertical surface and extends perpendicularly away from said lower vertical surface, and an upper vertical surface extending from said midpoint to a second end of said contact side end portion, removing a portion of said protrusion, and removing a section of said upper vertical surface to form a modified imaging process cartridge is installable in said second imaging device. 
         [0008]    A method of modifying an imaging process cartridge, the imaging process cartridge installable in a first imaging device and not installable in a second imaging device, the method comprising, providing the imaging process cartridge, said imaging process cartridge comprising a gear side end portion, said gear side end portion further comprising an upper vertical surface and a lower vertical surface, said lower vertical surface extending from a first end of said gear side end portion to about a midpoint of said gear side end portion, said upper vertical surface extending from said midpoint towards a second end of said gear side end portion, said gear side end portion further comprising an upper rib, a lower rib, a left connecting rib, a middle connecting rib and a right connecting rib mounted on said gear side end portion, said upper and lower ribs extending across said lower vertical surface and across a section of said upper vertical surface, said left connecting rib and said middle connecting rib located on said upper vertical surface and said right connecting rib located on said lower vertical surface, said upper, lower and connecting ribs protruding perpendicularly away from said lower vertical surface and said upper vertical surface, removing said upper rib, said left connecting rib, said middle connecting rib, and a part of said right connecting rib, and reducing said lower rib and said remaining right connecting rib in height to form a modified imaging process cartridge, wherein said lower rib and said remaining right connecting rib are about equal in height with said upper vertical surface, said modified imaging process cartridge installable in said second imaging device. 
         [0009]    A method of modifying an imaging process cartridge, the imaging process cartridge installable in a first imaging device and not installable in a second imaging device, the method comprising, providing the imaging process cartridge, said imaging process cartridge comprising a gear side end portion, said gear side end portion further comprising an upper vertical surface and a lower vertical surface, said lower vertical surface extending from a first end of said gear side end portion to about a midpoint of said gear side end portion, said upper vertical surface extending from said midpoint towards a second end of said gear side end portion, said gear side end portion further comprising an upper rib, a lower rib, a left connecting rib, a middle connecting rib and a right connecting rib mounted on said gear side end portion, said upper and lower ribs extending across said lower vertical surface and across a section of said upper vertical surface, said left connecting rib and said middle connecting rib located on said upper vertical surface and said right connecting rib located on said lower vertical surface, said upper, lower and connecting ribs protruding perpendicularly away from said lower vertical surface and said upper vertical surface, removing said upper rib, said left connecting rib, said middle connecting rib, and said right connecting rib, and reducing in height said lower rib to form a modified imaging process cartridge, wherein said lower rib is about equal in height with said upper vertical surface, said modified imaging process cartridge is installable in said second imaging device. 
         [0010]    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 
         [0011]      FIG. 1  shows a front perspective view of a prior art HP4730 toner cartridge. 
           [0012]      FIG. 2  shows an exploded front perspective view of the HP4730 toner cartridge, with the toner hopper removed. 
           [0013]      FIG. 3A  shows a side perspective view of a contact side end portion the cartridge of  FIG. 1 . 
           [0014]      FIG. 3B  shows a side view of the end portion of  FIG. 3A . 
           [0015]      FIG. 3C  shows a top view of the end portion of  FIG. 3A . 
           [0016]      FIG. 4A  shows a side perspective view of a contact side end portion of a prior art HP4700 printer cartridge. 
           [0017]      FIG. 4B  shows a side view of the end portion of  FIG. 4A . 
           [0018]      FIG. 4C  shows a top view of the end portion of  FIG. 4A . 
           [0019]      FIG. 5A  shows a side perspective view of a contact side end portion in accordance with one embodiment of the present invention. 
           [0020]      FIG. 5B  shows a side view of the end portion of  FIG. 5A . 
           [0021]      FIG. 5C  shows a top view of the end portion of  FIG. 5A . 
           [0022]      FIG. 6A  shows a side perspective view of a gear side end portion of the cartridge of  FIG. 1 . 
           [0023]      FIG. 6B  shows a side view of the end portion of  FIG. 6A . 
           [0024]      FIG. 7A  shows a side perspective view of a gear side end portion of the HP4700 printer cartridge. 
           [0025]      FIG. 7B  shows a side view of the end portion of  FIG. 7A . 
           [0026]      FIG. 8A  shows a side perspective view of a gear side end portion in accordance with one embodiment of the present invention. 
           [0027]      FIG. 8B  shows a side view of the end portion of  FIG. 8A . 
       
    
    
     DETAILED DESCRIPTION 
       [0028]    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. 
         [0029]    Within the printer industry, printer manufacturers have employed various techniques to differentiate between toner cartridges used in different printers. These techniques range from the obvious altering of the physical dimensions and shape of the toner cartridge or imaging drum unit to very subtle indentations or protrusions positioned at certain locations on the toner cartridge or imaging drum unit. For example, some printer manufacturers have installed protrusions such as fins or keys that extend out from the printer&#39;s toner cartridge compartment and are positioned inside a recess on the toner cartridge when the toner cartridge is installed inside the printer. In other printer types this arrangement may be reversed. The key may exist on the toner cartridge, and the recess may exist inside the toner cartridge compartment inside the printer. 
         [0030]    As new printer models are developed, “new” toner cartridges may also be introduced. In some cases, the new toner cartridge may contain exactly the same components as those of the previous printer model. However, the new toner cartridge or imaging drum unit may have slightly different physical packaging. In some cases, the printer manufacturer may install different keys, or keys in different locations. Changing the size, shape, orientation or location of the keys allows the printer manufacturer to differentiate between a previously introduced toner cartridges and those of newer models. This may allow the printer manufacturer to increase his margins by charging the consumer a premium for the new cartridge. 
         [0031]    Printer manufacturers may take advantage of existing toner cartridge technology by using an existing toner cartridge design and making only slight physical packaging modifications. For example, the black toner cartridge for the HP4700 color laser printer may have exactly the same internal components and even use the same toner as the black toner cartridge for the HP4730 color laser printer. In this case, the only packaging difference between the toner cartridges is the shape of the end portions on the waste bin of the cartridges. Additionally, within the same printer, the cartridges may be physically identical with the exception of the color toner installed in the cartridge. 
         [0032]    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. 
         [0033]    Part of the refurbishment process may include making physical alterations to the toner cartridge. For example, older cartridges may be altered or converted for use in other printer types. Alternatively, the remanufacturer may remove all of the physical restrictions from the toner cartridge, thus creating a “universal” cartridge that may be used in across multiple printers. The present invention provides a way of converting a printer toner cartridge of one type into one useable in another type of printer. 
         [0034]    As is discussed in greater detail in subsequent sections, a toner cartridge used in the HP4700 color laser printer is not physically compatible in the HP4730 color laser printer due to physical differences between the cartridges. Similarly, toner cartridges used in the HP4730 color laser printer are not compatible for use in the HP4700 color laser printer. 
         [0035]      FIG. 1  shows a front perspective view of a prior art toner cartridge  100  used in the HP4730 color laser printer. The cartridge  100  may be installed in any of the toner cartridge locations within the HP4730 color laser printer (black, cyan, magenta or yellow), depending on the color of toner contained in the cartridge  100 . Cartridge  100  comprises a toner hopper assembly  110  and a waste bin assembly  120 . On the ends of the cartridge  100  are a cartridge gear side end portion  200  as well as a toner hopper contact side end portion  130 , and a waste bin assembly contact side end portion  150 . During the remanufacturing process, the hopper assembly  110  and the waste bin assembly  120  are separated. 
         [0036]      FIG. 2  displays a front perspective exploded view of the waste bin assembly  120  with the toner hopper assembly  110  removed. The waste bin assembly  120  comprises a wiper blade  212  that removes any excess toner off of the OPC (Organic Photo Conductor) drum  214  into the waste bin  210  during the printing process. A drum shaft  216  is inserted into the OPC drum  214  allowing the drum to rotate. A PCR  218  (Primary Charge Roller) provides the OPC drum  214  with a uniform charge. Protecting the OPC drum  214  and other internal components is a drum shutter  218 . Those skilled in the art appreciate that during the laser printing process, the printer applies a laser which statically charges the OPC drum  214  with an appropriate charge corresponding to the image the printer is printing. The OPC drum  214  then collects toner from the toner hopper  110  which is then applied to the print media. After the toner is transferred to the printing media, the toner is fused onto the print media by a fuser assembly (not shown). 
         [0037]    The HP4700 color toner cartridges are not compatible in the HP4730 color laser printers due to physical differences in the waste bin assembly contact side end portion  150 .  FIG. 3A  displays a side perspective view of the waste bin assembly contact side end portion  150  for the HP4730 color laser printer. During the typical refurbishment process, the waste bin assembly contact side end portion  150  is not removed from the cartridge  100  because the waste bin assembly contact side end portion  150  is molded together with the waste bin assembly  120 . The waste bin assembly contact side end portion  150  is shown separated for illustrative purposes. 
         [0038]    As can be seen in  FIG. 3A , the waste bin assembly contact side end portion  150  has a protrusion  310  located at a first end  304  of a first lower vertical surface  302 . The protrusion  310  extends perpendicularly away from the lower vertical surface  302  by a height h 1 . The protrusion  310  aligns with a recess located in the printer cartridge location within the HP4730 color laser printer. The first lower vertical surface  302  connects to a second lower vertical surface  306 . The first lower vertical surface  302  and the second lower vertical surface  306  extend from about the first end point  304  to about a midpoint  312  of the waste bin assembly contact side end portion  150 .  FIGS. 3B and 3C  display a side view and a top view of the waste bin assembly contact side end portion  150  respectively. 
         [0039]    The waste bin assembly contact side end portion  150  also has a first upper vertical surface  320  and a second upper vertical surface  330  which extend from about the mid point  312  to about a second end point  360 . As shown can best be seen in  FIG. 3C , a height difference h 4  exists between the first upper vertical surface  320  and the second upper vertical surface  330 . In the embodiment shown in  FIGS. 3A-C , the second end point  360  is located at the handle end  340  of the waste bin assembly contact side end portion  150 . 
         [0040]    As shown in  FIGS. 4A-C , the waste bin assembly contact side end portion  400  for the HP4700 has some slight physical differences. The waste bin assembly contact side end portion  400  has a slightly taller protrusion  410  when compared to the waste bin assembly contact side end portion  150  ( FIGS. 3A-C ). The difference between protrusion  410  and protrusion  310  is h 2 -h 1 . Protrusion  410  is located at a first end  404  on a lower vertical surface  402  that extends from the first end  404  to about a mid point  412 . The protrusion  410  is mounted on the lower vertical surface  402  at about the same location as protrusion  310  is located on the first lower vertical surface  304 . 
         [0041]    In contrast to the waste bin assembly contact side end portion  150 , the waste bin assembly contact side end portion  400  only has an upper vertical surface  420  that extends from about the mid point  412  to a second end point  460 . The combination of the height differential of the protrusions h 2 -h 1 , as well as the lack of a second upper vertical surface  330  prevents the HP4700 toner cartridges from being used in the HP4730 color laser printer. 
         [0042]    In accordance with one embodiment of the present invention, an HP4700 toner cartridge may be modified in order to be compatible with the HP4730 color laser printer as shown in  FIGS. 5A-C .  FIGS. 5A-C  illustrate a waste bin assembly contact side end portion  400  that has undergone the conversion process as described hereinafter. The converted waste bin assembly contact side end portion  500  comprises a first upper vertical surface  520  and a second upper vertical surface  530  similar to the waste bin assembly contact side end portion  150  ( FIGS. 3A-C ). The converted waste bin assembly contact side end portion  500  also comprises a protrusion  510  of height h 3  located at a first end  504  on a lower vertical surface  502 . Lower vertical surface  502  extends from the first end  504  to about a mid point  512 . 
         [0043]    As part of the conversion process, the height h 2  of the protrusion  410  is reduced be removing a portion  570  (shown as a dashed profile in  FIG. 5C ) of protrusion  410 . The height h 3 of protrusion  510  is about equal to height h 1  of protrusion  310 . Portion  570  may be removed using any type of cutting device. For example a hack saw, file, band saw, jig saw, Rotozip™, Dremmel™ or other similar tool may be utilized. Although not recommended, the portion  570  may be removed by melting the protrusion  410 . Typically, the portion  570  is approximately 0.1″ (2.54 mm) in height. Once the protrusion  510  has been modified, a file or other type of tool may be used in order to smooth out any rough surfaces left over from the conversion process. 
         [0044]    The next step in converting the waste bin assembly contact side end portion  400  in accordance with the preferred embodiment includes removing a section of the upper vertical surface  420 . As represented by the dashed profile in  FIG. 5B , the section removed extends from about the mid point  512  to about the second end point  560 . The depth of the section removed (difference between the first upper vertical surface  520  and the second upper vertical surface  530 ) is height d 1 . Typically the depth d 1  is about 0.2″ (5.08 mm). The section has a front height h 6  of about 0.3″ (7.62 mm) and a rear height h 7  of about 0.2″ (5.08 mm). Once the section has been removed, a file or other type of tool may be used in order to smooth out any rough surfaces left over from the conversion process. 
         [0045]    In yet another alternative embodiment of the present invention, a patch may be inserted where the section has been removed in order to provide a more aesthetically appealing converted waste bin assembly contact side end portion  500   
         [0046]    In another embodiment of the present invention, an HP4730 waste bin assembly may be converted to be usable in an HP4700 color laser printer.  FIG. 6A  displays a side perspective view of cartridge gear side end portion  200  of the HP4730 toner cartridge  100 .  FIG. 6B  displays a side view of cartridge gear side end portion  200 . The cartridge gear side end portion  200  comprises an upper vertical surface  602  and a lower vertical surface as well as an upper rib  610  and a lower rib  620 . The lower vertical surface  604  extends from a first end  606  to about a mid point  608 . The upper vertical surface  602  extends from the mid point  608  to point about half way between the mid point  608  and a second end  612 . The upper rib  610  and lower rib  620  extend across the lower vertical surface 604  and across part of the upper vertical surface  602 . Connecting the upper rib  610  to the lower rib are a left connecting rib  630 , a middle connecting rib  640  and a right connecting rib  650 . Left connecting rib  630  and middle connecting rib  640  are located on the upper vertical surface  602  while right connecting rib  650  is located on the lower vertical surface  604 . The ribs ( 610 ,  620 ,  630 ,  640  and  650 ) are about equal in height and protrude away from the upper vertical surface  602  by approximately 0.1″ (2.54 mm) 
         [0047]    Cartridge gear side end portion  200  also has a bottom rib  670  and a bottom connecting rib  672 . The bottom connecting rib  672  extends from the juncture of the lower rib  620  and the right connecting rib  650  to the bottom rib  670 . Bottom rib  670  extends from the bottom connecting rib  672  to mid point  608 . Unlike the other ribs ( 610 ,  620 ,  630 ,  640  and  650 ) bottom rib  670  and bottom connecting rib  672  are planarlly parallel with upper vertical surface  602  and thus do not extend beyond upper vertical surface  602 . 
         [0048]      FIGS. 7A and 7B  illustrate a side perspective and side view respectively of a cartridge gear side end portion  700  of the HP4700 toner cartridge. Similar to cartridge gear side end portion  200 , cartridge gear side end portion  700  also has an upper vertical surface  702  and a lower vertical surface  704  as well as a bottom rib  770 , a bottom connecting rib  772  and a lower rib  710  mounted on lower vertical surface  704 . Lower vertical surface extends from a first end  706  to about a mid point  708 . Upper vertical surface  702  extends from the mid point  708  to point about half way between the mid point  708  and a second end  712 . Like bottom rib  670  and bottom connecting rib  672  ( FIGS. 6A  &amp; B), bottom connecting rib  772  and lower rib  710  are planarlly parallel with upper vertical surface  702  and thus do not extend beyond upper vertical surface  702 . 
         [0049]    When comparing cartridge gear side end portion  200  with cartridge gear side end portion  700 , the physical differences of ribs ( 610 ,  620 ,  630 ,  640  and  650 ) are apparent. Within the HP4700 color laser printer, there is no recess corresponding to ribs  610 ,  620 ,  630 ,  640  and  650 . Therefore, if toner cartridge  100  (intended for use in the HP4730 color laser printer) were to be inserted into the HP4700 color laser printer, the ribs would restrict the cartridge from being fully inserted into the toner cartridge compartment (not shown). 
         [0050]    In accordance with another embodiment of the present invention, toner cartridge  100  may be modified in order to allow the modified toner cartridge  800  to be used in other types of printers as shown in  FIGS. 8A  and B.  FIG. 8A  illustrates a side perspective view of a modified cartridge gear side end portion  800 .  FIG. 8B  displays a side view of modified cartridge gear side end portion  800 . 
         [0051]    As can be seen in  FIGS. 8A  &amp; B, the upper rib  610  of cartridge gear side end portion  200  has been removed entirely. In addition, left connecting rib  630 , middle connecting rib  640  and a part of right connecting rib  650  have also been removed (as shown outlined by the dashed lines). The height of lower rib  820  and remaining right connecting rib  850  are reduced so that they are roughly planarlly parallel with upper vertical surface  802  and thus do not extend beyond upper vertical surface  802 . 
         [0052]    One way of removing the upper rib  610 , left connecting rib  630 , middle connecting rib  640  and a part of right connecting rib  650  is to use a hack saw, band saw, jig saw, RotoZip™, Dremmel™ or other similar tool. Although not recommended, the ribs  610 ,  620 ,  640 , and  650  may be melted down as well. In addition to removing ribs  610 ,  620 ,  640 , and  650 , the remaining ribs that protrude above the upper vertical surface  802  (lower rib  820  and right connecting rib  850 ) may be reduced in height the same tool used to remove the other ribs ( 610 ,  620 ,  640 , and  650 ). Once the ribs ( 610 ,  620 ,  640 , and  650 ) have been removed and the remaining ribs ( 820 ,  850 ) have been reduced in height, a file or other type of tool may be used in order to smooth out any rough surfaces left over from the conversion process. In yet another embodiment of the present invention, the right connecting rib  850  may be removed completely. 
         [0053]    A waste bin assembly  120  comprising the converted waste bin assembly contact side end portion  500  ( FIGS. 5A-C ) and cartridge gear side end portion  700  ( FIGS. 7A  &amp; B) allows the toner cartridge  100  to be used universally in either the HP4700 or HP4730 color laser printers. Similarly, a waste bin assembly  120  comprising the converted gear side end portion  800  ( FIGS. 8A  &amp; B) used with a waste bin assembly contact side end portion  300  ( FIGS. 5A-C ) allows the toner cartridge to be used universally in either the HP4700 or HP4730 color laser printers. 
         [0054]    Within the toner cartridge or imaging drum unit, an electronic identification chip may be installed. The identification chip may contain information relating to the printer type, printer manufacturer, amount of toner contained in the toner cartridge and so forth. Even if the physical restrictions between cartridge types have been removed, the electronic identification chip may need to be replaced with a compatible electronic chip in order to allow the toner cartridge or imaging drum unit to function properly in its new location or printer. 
         [0055]    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.