Patent Publication Number: US-10310438-B2

Title: Systems and methods for remanufacturing imaging components

Description:
This application is a continuation of U.S. application Ser. No. 15/358,715 filed Nov. 22, 2016, which is a continuation of U.S. application Ser. No. 14/532,395 filed Nov. 4, 2014, which issued as U.S. Pat. No. 9,501,024, which is a continuation of U.S. application Ser. No. 13/444,511 filed on Apr. 11, 2012, which issued as U.S. Pat. No. 8,879,959, which is a continuation of U.S. application Ser. No. 13/283,684 filed on Oct. 28, 2011, which issued as U.S. Pat. No. 8,538,295, which is a continuation of U.S. application Ser. No. 12/902,625 filed on Oct. 12, 2010, which issued as U.S. Pat. No. 8,073,364, which is a continuation of U.S. application Ser. No. 11/825,262 filed on Jul. 5, 2007, which issued as U.S. Pat. No. 7,813,676, all of which are incorporated by reference herein in its entirety. 
    
    
     BACKGROUND 
     The present invention generally relates to manufacturing, remanufacturing or repairing replaceable imaging components, and more particularly to apparatus and techniques for providing a drive gear for a drum or roller, such as an organic photo conductor (OPC) drum, for example, of a replaceable imaging cartridge adapted for holding marking material, such as toner. 
     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. 
     Laser printer toner cartridges are typically composed of two portions. One of these sections is the waste bin assembly which houses the OPC drum. The OPC may include a drive gear which engages with a printer drive member. During the remanufacturing of a laser printer toner cartridge, the OPC drum may need to be replaced due to the wear or damage of the OPC drum. The replacement OPC drum may include a replacement drive gear, or gear, attached to one end of the replacement OPC drum. The present invention provides for an improved replacement drive gear. 
     SUMMARY 
     In one aspect of the present invention, a drive gear for a generally cylindrical imaging component includes a body for engaging the generally cylindrical imaging component; a cylindrical shaft attached to the body, the cylindrical shaft having an end surface; and three prongs extending longitudinally outward from the end surface. 
     In another aspect of the present invention, an imaging apparatus assembly includes a drive mechanism including a helical recess; and a drive gear including a body for engaging a generally cylindrical imaging component; a cylindrical shaft attached to the body, the cylindrical shaft having an end surface; and three prongs extending longitudinally outward from the end surface and engaging the helical recess. 
     In another aspect of the present invention, an imaging apparatus assembly includes a generally cylindrical imaging component; and a drive gear including a body engaging a generally cylindrical imaging component; a cylindrical shaft attached to the body, the cylindrical shaft having an end surface; and three prongs extending longitudinally outward from the end surface. 
     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 
         FIG. 1  shows a perspective view of a prior art drive mechanism; 
         FIGS. 2-17  show perspective views of multiple embodiments of a drive gear in accordance with the present invention; and 
         FIG. 18  shows a drive gear and OPC drum in accordance with the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     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 providing a drive gear for a drum or roller, such as an organic photo conductor (OPC) drum, for example, of a replaceable imaging cartridge adapted for holding marking material, 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. 
       FIG. 1  shows a prior art drive mechanism  100 . The drive mechanism  100  may include a body  102  having a raised section  104 . A helical recess  106  may be formed in the raised section  104 . The raised section  104  may include an outer cylindrical surface  104   a . In operation, the drive mechanism  100  is part of a printer and engages a gear (not shown) having a shaped helical extrusion on an imaging cartridge, and causes the gear with the helical extrusion to rotate. Further details of such a prior art drive mechanism  100  and gear are disclosed in U.S. Pat. No. 6,400,914 which is incorporated by reference herein in its entirety. 
       FIG. 2  shows a drive gear  200  in accordance with the present invention. One end of the drive gear  200  is adapted to be attached to a hollow roller or generally cylindrical imaging component, such as an OPC drum. The other end of the drive gear  200  is adapted to engage the helical recess  106  of the drive mechanism  100  of a printer. The drive gear  200  includes a body  202  for engaging the generally cylindrical imaging component and a cylindrical shaft  204  attached to the body  202 . The cylindrical shaft  204  has an end surface  206 . Three prongs  208  extend longitudinally outward from the end surface  206  and are shaped to engage the helical recess  106  of the drive mechanism  100 . Each of the three prongs  208  may be generally triangular in shape with one vertex  208   a  of each triangular shaped prong  208  being generally rounded. 
     When the user closes a door of the printer, the drive mechanism  100  slides onto the cartridge drive gear  200  so that the three drive gear prongs  208  are inserted into the helical recess  106 . As the printer drive mechanism  100  rotates, the three prongs  208  are engaged, and the entire cartridge drive gear  200  rotates, which in turn drives an OPC (not shown) attached to the drive gear  200 . In this embodiment, only the OPC is rotated by this drive interface, however this design is not limited only to this embodiment. The drive gear may include one or more gears which drive the rest of the cartridge components in addition to the OPC. 
       FIG. 3  shows a drive gear  300  in accordance with the present invention. One end of the drive gear  300  is adapted to be attached to a hollow roller or generally cylindrical imaging component, such as an OPC drum. The other end of the drive gear  300  is adapted to engage the helical recess  106  of the drive mechanism  100  of a printer. The drive gear  300  includes a body  302  for engaging the generally cylindrical imaging component and a cylindrical shaft  304  attached to the body  302 . The cylindrical shaft  304  has an end surface  306 . Three prongs  308  extend longitudinally and radially outward from the end surface  306  and are shaped to engage the helical recess  106  of the drive mechanism  100 . Each of the prongs  308  may be generally rectangular in cross section. Bracing members  308   a  may be disposed between the prongs  308 . The drive gear  300  may include one or more gears  310  which drive the additional cartridge components. 
       FIG. 4  shows a drive gear  400  in accordance with the present invention. One end of the drive gear  400  is adapted to be attached to a hollow roller or generally cylindrical imaging component, such as an OPC drum. The other end of the drive gear  400  is adapted to engage the helical recess  106  of the drive mechanism  100  of a printer. The drive gear  400  includes a body  402  for engaging the generally cylindrical imaging component and a cylindrical shaft  404  attached to the body  402 . The cylindrical shaft  404  has an end surface  406 . Three prongs  408  extend longitudinally and radially outward from the end surface  406  and are shaped to engage the helical recess  106  of the drive mechanism  100 . Each of the prongs  408  may be generally rectangular in cross section. The drive gear  400  may include one or more gears  410  which drive the additional cartridge components. 
       FIG. 5  shows a drive gear  500  in accordance with the present invention. One end of the drive gear  500  is adapted to be attached to a hollow roller or generally cylindrical imaging component, such as an OPC drum. The other end of the drive gear  500  is adapted to engage the helical recess  106  of the drive mechanism  100  of a printer. The drive gear  500  includes a body  502  for engaging the generally cylindrical imaging component and a cylindrical shaft  504  attached to the body  502 . The cylindrical shaft  504  has an end surface  506 . Three prongs  508  extend longitudinally outward from the end surface  506  and are shaped to engage the helical recess  106  of the drive mechanism  100 . Each of the prongs  508  may be generally circular in cross section and may be inclined at a slight angle to the end surface  506  in a twisted fashion. The drive gear  500  may include one or more gears  510  which drive the additional cartridge components. 
       FIG. 6  shows a drive gear  600  in accordance with the present invention. One end of the drive gear  600  is adapted to be attached to a hollow roller or generally cylindrical imaging component, such as an OPC drum. The other end of the drive gear  600  is adapted to engage the helical recess  106  of the drive mechanism  100  of a printer. The drive gear  600  includes a body  602  for engaging the generally cylindrical imaging component and a cylindrical shaft  604  attached to the body  602 . The cylindrical shaft  604  has an end surface  606 . Three prongs  608  extend longitudinally and latitudinally outward from the end surface  606  and are shaped to engage the helical recess  106  of the drive mechanism  100 . Each of the prongs  608  may include a longitudinal element  608   a  and a latitudinal element  608   b . The drive gear  600  may include one or more gears  610  which drive the additional cartridge components. 
       FIG. 7  shows a drive gear  700  in accordance with the present invention. One end of the drive gear  700  is adapted to be attached to a hollow roller or generally cylindrical imaging component, such as an OPC drum. The other end of the drive gear  700  is adapted to engage the helical recess  106  of the drive mechanism  100  of a printer. The drive gear  700  includes a body  702  for engaging the generally cylindrical imaging component and a cylindrical shaft  704  attached to the body  702 . The cylindrical shaft  704  has an end surface  706 . A triangular shaped element  708  extends outward from the end surface  706  and is shaped to engage the helical recess  106  of the drive mechanism  100 . The drive gear  700  may include one or more gears  710  which drive the additional cartridge components. 
       FIG. 8  shows a drive gear  800  in accordance with the present invention. One end of the drive gear  800  is adapted to be attached to a hollow roller or generally cylindrical imaging component, such as an OPC drum. The other end of the drive gear  800  is adapted to engage the helical recess  106  of the drive mechanism  100  of a printer. The drive gear  800  includes a body  802  for engaging the generally cylindrical imaging component and a cylindrical shaft  804  attached to the body  802 . The cylindrical shaft  804  has an end surface  806 . A cam shaped element  808  extends outward from the end surface  806  and is shaped to engage the helical recess  106  of the drive mechanism  100 . The drive gear  800  may include one or more gears  810  which drive the additional cartridge components. 
       FIG. 9  shows a drive gear  900  in accordance with the present invention. One end of the drive gear  900  is adapted to be attached to a hollow roller or generally cylindrical imaging component, such as an OPC drum. The other end of the drive gear  900  is adapted to engage the helical recess  106  of the drive mechanism  100  of a printer. The drive gear  900  includes a body  902  for engaging the generally cylindrical imaging component and a cylindrical shaft  904  attached to the body  902 . The cylindrical shaft  904  has an end surface  906 . A generally triangular shaped element  908  extends and flares outward from the end surface  906  and is shaped to engage the helical recess  106  of the drive mechanism  100 . The drive gear  900  may include one or more gears  910  which drive the additional cartridge components. 
       FIG. 10  shows a drive gear  1000  in accordance with the present invention. One end of the drive gear  1000  is adapted to be attached to a hollow roller or generally cylindrical imaging component, such as an OPC drum. The other end of the drive gear  1000  is adapted to engage the helical recess  106  of the drive mechanism  100  of a printer. The drive gear  1000  includes a body  1002  for engaging the generally cylindrical imaging component and a cylindrical shaft  1004  attached to the body  1002 . The cylindrical shaft  1004  has an end surface  1006 . A six-pointed star shaped element  1008  extends outward from the end surface  1006  and is shaped to engage the helical recess  106  of the drive mechanism  100 . The drive gear  1000  may include one or more gears  1010  which drive the additional cartridge components. 
       FIG. 11  shows a drive gear  1100  in accordance with the present invention. One end of the drive gear  1100  is adapted to be attached to a hollow roller or generally cylindrical imaging component, such as an OPC drum. The other end of the drive gear  1100  is adapted to engage the helical recess  106  of the drive mechanism  100  of a printer. The drive gear  1100  includes a body  1102  for engaging the generally cylindrical imaging component and a cylindrical shaft  1104  attached to the body  1102 . The cylindrical shaft  1104  has an end surface  1106 . An off-center element  1108  having two lobes  1108   a  extends outward from the end surface  1106  and is shaped to engage the helical recess  106  of the drive mechanism  100 . The drive gear  1100  may include one or more gears  1110  which drive the additional cartridge components. 
       FIG. 12  shows a drive gear  1200  in accordance with the present invention. One end of the drive gear  1200  is adapted to be attached to a hollow roller or generally cylindrical imaging component, such as an OPC drum. The other end of the drive gear  1200  is adapted to engage the helical recess  106  of the drive mechanism  100  of a printer. The drive gear  1200  includes a body  1202  for engaging the generally cylindrical imaging component and a cylindrical shaft  1204  attached to the body  1202 . The cylindrical shaft  1204  has an end surface  1206 . A tri-lobe element  1208  flares outward from the end surface  1206  and is shaped to engage the helical recess  106  of the drive mechanism  100 . The drive gear  1200  may include one or more gears  1210  which drive the additional cartridge components. 
       FIG. 13  shows a drive gear  1300  in accordance with the present invention. One end of the drive gear  1300  is adapted to be attached to a hollow roller or generally cylindrical imaging component, such as an OPC drum. The other end of the drive gear  1300  is adapted to engage the helical recess  106  of the drive mechanism  100  of a printer. The drive gear  1300  includes a body  1302  for engaging the generally cylindrical imaging component and a cylindrical shaft  1304  attached to the body  1302 . The cylindrical shaft  1304  has an end surface  1306 . A tri-lobe element  1308  flares outward from the end surface  1306  and is shaped to engage the helical recess  106  of the drive mechanism  100 . The drive gear  1300  may include one or more gears  1310  which drive the additional cartridge components. 
       FIG. 14  shows a drive gear  1400  in accordance with the present invention. One end of the drive gear  1400  is adapted to be attached to a hollow roller or generally cylindrical imaging component, such as an OPC drum. The other end of the drive gear  1400  is adapted to engage the helical recess  106  of the drive mechanism  100  of a printer. The drive gear  1400  includes a body  1402  for engaging the generally cylindrical imaging component and a cylindrical shaft  1404  attached to the body  1402 . The cylindrical shaft  1404  has an end surface  1406 . A tri-lobe element  1408  extends outward from the end surface  1406  and is shaped to engage the helical recess  106  of the drive mechanism  100 . As shown in  FIG. 14 , the tri-lobe element  1408  narrows inwards towards a rotational axis of the drive gear  1400  as the tri-lobe element  1408  extends outward from the end surface  1406 . The drive gear  1400  may include one or more gears  1410  which drive the additional cartridge components. 
       FIG. 15  shows a drive gear  1500  in accordance with the present invention. One end of the drive gear  1500  is adapted to be attached to a hollow roller or generally cylindrical imaging component, such as an OPC drum. The other end of the drive gear  1500  is adapted to engage the drive mechanism  100  of a printer. The drive gear  1500  includes a body  1502  for engaging the generally cylindrical imaging component and a cylindrical shaft  1504  attached to the body  1502 . The cylindrical shaft  1504  has an end surface  1506 . Three prongs  1508  extend longitudinally and radially outward from the end surface  1506  and are shaped to grip outer cylindrical surface  104   a  of the drive mechanism  100 . The drive gear  1500  may include one or more gears  1510  which drive the additional cartridge components. 
       FIG. 16  shows a drive gear  1600  in accordance with the present invention. One end of the drive gear  1600  is adapted to be attached to a hollow roller or generally cylindrical imaging component, such as an OPC drum. The other end of the drive gear  1600  is adapted to engage the drive mechanism  100  of a printer. The drive gear  1600  includes a body  1602  for engaging the generally cylindrical imaging component and a cylindrical shaft  1604  attached to the body  1602 . The cylindrical shaft  1604  has an end surface  1606 . Three prongs  1608  extend longitudinally and radially outward from the end surface  1506  and are shaped to grip the outer cylindrical surface  104   a  of the drive mechanism  100 . A cylindrical element  1612  extends outward to engage the helical recess  106  of the drive mechanism  100 . The drive gear  1600  may include one or more gears  1610  which drive the additional cartridge components. 
       FIG. 17  shows a drive gear  1700  in accordance with the present invention. One end of the drive gear  1700  is adapted to be attached to a hollow roller or generally cylindrical imaging component, such as an OPC drum. The other end of the drive gear  1700  is adapted to engage the helical recess  106  of the drive mechanism  100  of a printer. The drive gear  1700  includes a body  1702  for engaging the generally cylindrical imaging component and a cylindrical shaft  1704  attached to the body  1702 . The cylindrical shaft  1704  has an end surface  1706 . A triangular shaped element  1708  extends longitudinally outward from the end surface  1706  and is shaped to engage the helical recess  106  of the drive mechanism  100 . The element may generally triangular in shape but missing one vertex  1708   a . A cylindrical shaped element  1712  is shaped to engage the outer cylindrical surface  104   a  of the drive mechanism  100 . The drive gear  1700  may include one or more gears  1710  which drive the additional cartridge components. 
       FIG. 18  shows the drive gear  200  attached to an OPC drum  1800  in accordance with the present invention. 
     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.