Patent Publication Number: US-10310415-B1

Title: System and method for removing pins from a print cartridge

Description:
BACKGROUND 
     The application generally relates to imaging, or printer, cartridges. 
     SUMMARY 
     Printing systems, such as high volume printing devices (e.g., network printers, photocopiers, etc.), typically use toner cartridges which store and transmit toner to an intended medium, such as paper. Once the toner has depleted, the used toner cartridge is removed from the printing system, and typically disposed of. Remanufacturing of used toner cartridges permits the toner cartridges to be reused rather than disposed of in landfills. 
     Toner cartridges come in a variety of configurations. Although specific constructions vary among manufacturers and printers, many toner cartridges include components such as a toner hopper, a waste hopper, and a variety of toner-regulating blades, a developer roller, a primary charge roller, and an organic photo-conductor drum. 
     To avoid discarding useful materials and to thereby reduce the environmental impact of printing operations, many toner cartridges may be remanufactured. Remanufacturing involves collecting used toner cartridges that, prior to their use, were brand new cartridges typically supplied by the manufacturer of the printer with which the cartridges are compatible. These cartridges are often referred to in the art as “OEM cartridges” because they are supplied by the original equipment manufacturer, i.e., the manufacturer of the printer and the compatible printer cartridge. 
     Remanufacturing of toner cartridges typically includes, among other things, disassembling the toner cartridge, cleaning the toner cartridge, refilling the toner hopper with new toner, repairing or replacing worn or damaged components, and reassembling the toner cartridge. 
     In one embodiment, the invention provides a method of disassembling a used toner cartridge having a toner hopper and a waste hopper coupled to the toner hopper via a first pin and a second pin. The first pin is removably coupled within a first connection joint and the second pin is removably coupled within a second connection joint. The method includes the steps of (a) providing a pin removal arm having a first push-out pin and a second push-out pin; (b) positioning the pin removal arm between the first connection joint and the second connection joint; (c) displacing the first pin of the toner hopper relative to the first connection joint with the first push-out pin by moving the pin removal arm towards the first pin; and (d) displacing the second pin of the toner hopper relative to the second connection joint with the second push-out pin by moving the pin removal arm towards the second pin. 
     In another embodiment, the invention provides a toner cartridge disassembly machine for at least partially disassembling a toner cartridge. The toner cartridge includes a toner hopper and a waste hopper coupled to the toner hopper via a first pin and a second pin. The first pin is removably coupled within a first connection joint and the second pin is removably coupled within a second connection joint. The disassembly machine includes a base, a docking station supported by the base and capable of receiving the toner cartridge, and a carrier frame movably coupled to the base. The disassembly machine further includes a pin removal arm supported by the carrier frame. The pin removal is movable into a position between the first connection joint and the second connection joint. The pin removal arm includes a first push-out pin configured to interact with the first pin and a second push-out pin configured to interact with the second pin. 
     Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a toner cartridge disassembly machine according to some embodiments of the application, illustrating a toner cartridge supported therein. 
         FIG. 2  is a side plan view of the toner cartridge of  FIG. 1 . 
         FIG. 3  is an enlarged perspective view of the toner cartridge disassembly machine, illustrating a main carrier frame and a pin removal arm. 
         FIG. 4  is a perspective view of the pin removal arm of  FIG. 3 . 
         FIG. 5  is a top view of the pin removal arm adjacent the toner cartridge. 
         FIG. 6  is a top view of the pin removal arm inserted through a gap existing within the toner cartridge. 
         FIG. 7  is a top view of the pin removal arm being co-axially aligned with a pair of pins of the toner cartridge. 
         FIG. 8  is a top view of the pin removal arm displacing one of the pins relative to the toner cartridge. 
         FIG. 9  is a top view of the pin removal arm displacing the other one of the pins relative to the toner cartridge. 
     
    
    
     DETAILED DESCRIPTION 
     Before any embodiments of the application are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. 
       FIG. 1  illustrates a toner cartridge disassembly machine  10  according to some embodiments of the application. The toner cartridge disassembly machine  10  is configured to at least partially dissemble a toner cartridge  300  during operation of the machine  10 , as described in further detail below. The toner cartridge  300  is a consumable component used in a printing system (e.g., network printers, laser printers, photocopiers, etc.). The toner cartridge  300  stores and, in cooperation with components of a compatible printer, transfers toner to an intended medium (e.g., paper). 
     The toner cartridge  300  of  FIG. 2  is an “all-in-one” cartridge and includes the following components or elements: a toner hopper  305  for storing a mass of toner; a waste hopper  310  for storing residual toner; a developer roller (i.e., a magnetic roller or a developer unit)  315 ; an organic photo-conductor (OPC) drum  320 ; and a primary charge roller (not shown) adjacent the OPC drum  320 . The illustrated toner cartridge  300  further includes a wiper blade embedded within the waste hopper  310  and disposed adjacent the OPC drum  320 . The wiper blade contacts the OPC drum  320  and wipes residual toner (i.e., toner remaining on the OPC drum  320  after transfer to the intended medium) from the OPC drum  320 . The wiped residual toner is collected by a waste hopper  310 . The toner hopper  305  is pivotably connected to the waste hopper  310  via connection joints  325 A,  325 B (although only one is shown in  FIG. 2 ). A pair of pins  330 A,  330 B ( FIG. 5 ) are selectively received within corresponding connection joints  325 A,  325 B to couple the toner hopper  305  to the waste hopper  310 . The pins  330 A,  330 B are co-axially aligned along a pin axis  338 . As shown, a void or air gap  340  exists between the toner hopper  305  and the waste hopper  310  in the space between the OPC drum  320  and the joints  325 A,  325 B. 
     During a printing sequence, toner is collected from the toner hopper  305  by the rotating developer roller  315  and magnetically or electrostatically transferred from the developer roller  315  to the OPC drum  320 . A laser system having a laser beam, located within the printing system, scans an electrostatic image onto the OPC drum  320  with the laser beam. In some printers, the electrostatic image produced by the laser corresponds to the image to be printed. In other printers, the laser forms an electrostatic image that is a negative of the image that is to be printed. Regardless of the specific configuration, toner carried by the developer roller  315  is electrostatically attracted to the electrostatic image produced on the OPC drum  320  by the laser beam. The OPC drum  320  then applies the toner, which is in a pattern corresponding to the desired image, onto the intended medium by direct contact or by further electrostatic transfer. The toner is then fused to the intended medium, typically by way of a heating element (e.g., a fuser). 
     With reference to  FIGS. 1 and 3 , the toner cartridge disassembly machine  10  includes a base  14 , a protection screen  18  extending upward from the base  14 , and a user control interface  22  where an operator is able to input various parameters to initiate a pin removal sequence. The disassembly machine  10  further includes a cartridge docking station  26  that receives and temporarily supports the toner cartridge  300  during operation. Specifically, the toner cartridge  300  includes posts  335  extending away from the waste hopper  310  that are supported within the docking station  26  by a pair of upright walls  30 . The upright walls  30  effectively create a cradle for the posts  335  to rest upon. Once the posts  335  are resting atop the upright walls  30 , the toner cartridge  300  is supported in an elevated position relative to the base  14  and inhibited from inadvertent lateral movement. The docking station  26  is configured to receive different sizes of toner cartridges while ensuring consistent positioning of the gap  340  within the docking station  26 . 
     The cartridge docking station  26  further includes a locking arm  34  that is pneumatically driven by a locking arm actuator  38  to secure the toner cartridge  300  in the docking station  26 . The locking arm actuator  38  defines a locking arm axis  42  along which the locking arm  34  moves and rotates about. As shown in  FIG. 1 , the locking arm  34  is in a blocking position (shown in solid lines), in which the locking arm  34  is in contact with and effectively interferes with the toner cartridge  300  from being removed from the docking station  26 . When the toner cartridge  300  is ready to be removed from the docking station  26 , the locking arm  34  is moved to an unblocking position (shown in phantom lines). Specifically, the locking arm  34  is actuated vertically away from the toner cartridge  300  along the locking arm axis  42 , and subsequently rotated (approximately 90 degrees) about the locking arm axis  42  until the locking arm  34  is positioned outside of the vertical footprint of the toner cartridge  300  for ease of removal of the cartridge  300 . Although the locking arm actuator  38  is defined as a pneumatic actuator, the actuator  38  may alternately be a different type of suitable actuator. 
     With continued reference to  FIGS. 1 and 3 , the toner cartridge disassembly machine  10  further includes a main carrier frame  46  movably coupled to the base  14  via guide rails  50  and a pair of auxiliary carrier frames  54 ,  58  movably supported on the main carrier frame  46 . Specifically, the first auxiliary carrier frame  54  is movably coupled to the main carrier frame  46  via guide rails  62 , while the second auxiliary carrier frame  58  is movably coupled to the first auxiliary carrier frame  54  via guide rails  66 . The main carrier frame  46  is capable of sliding in the y-direction (as denoted by arrow  70 ) on rails  50  and both the first and second auxiliary carrier frames  54 ,  58  are capable of sliding in the x-direction (as denoted by arrow  74 ) on rails  62 ,  66 , respectively. As such, the first and second auxiliary carrier frames  54 ,  58  move perpendicular relative to the main carrier frame  46 . With that said, the first auxiliary carrier frame  54  moves in a direction parallel relative to the second auxiliary carrier frame  58 . The guide rails  50 ,  62 ,  66  of the illustrated embodiment are conventional linear slide rails with corresponding dry bearing mounts captured on the linear slide rails. In other embodiments, ball bearing mounts may alternatively be coupled to the linear slide rails. 
     The main carrier frame  46  includes three separate pneumatic actuators—a first actuator  78  fixedly coupled between the base  14  and the main carrier frame  46 , a second actuator  82  fixedly coupled between the main carrier frame  46  and the first auxiliary carrier frame  54 , and a third actuator  86  fixedly coupled between the first and second auxiliary carrier frames  54 ,  58 . When activated, a piston rod  90  of the first actuator  78  moves the main carrier frame  46  along the guide rails  50  in the y-direction. Similarly, a piston rod  94  of the second actuator  82  moves the first auxiliary carrier frame  54  along the guides rails  62  in the y-direction and a piston rod  98  of the third actuator  86  moves the second auxiliary carrier frame  58  along the guide rails  66  in the y-direction. Although originally defined as pneumatic actuators, the actuators  78 ,  82 ,  86  may alternately be a different type of suitable actuator. 
     With reference to  FIG. 3 , limit screws  102  are provided in the movement path of each actuator  78 ,  82 ,  86  to limit the range of motion of each actuator  78 ,  82 ,  86  within a predetermined distance. The limit screws  102  are capable of being adjusted to change the predetermined distance that each actuator  78 ,  82 ,  86  is permitted to travel. The limit screws  102  of the illustrated embodiment are “hard-stops”, such that the limit screws  102  interfere and inhibit movement of the actuators  78 ,  82 ,  86  beyond the predetermined distance that is set. In other embodiments, the limit screws  102  may alternatively be limit switches that send an electronic signal to a controller, resulting in deactivation of the corresponding actuator  78 ,  82 ,  86  upon contact with the limit switches. 
     With reference to  FIG. 4 , the toner cartridge disassembly machine  10  further includes a pin removal arm  106  that is coupled to and movable with the second auxiliary carrier frame  58 . In fact, the pin removal arm  106  is cantilevered away from the second auxiliary carrier frame  58  along the x-direction  74 , such that a first end  110  of the pin removal arm  106  is rigidly fixed to the second auxiliary carrier frame  58 , whereas a distal second end  114  of the pin removal arm  106  is unsupported and spaced away in the x-direction  74  from the second auxiliary carrier frame  58 . The pin removal arm  106  is parallel to the rails  66  and includes a pair of push-out pins  118 A,  118 B removably coupled to the pin removal arm  106  through respective pin housings  122 A,  122 B. The pin housings  122 A,  122 B are fastened to the pin removal arm  106  with screws, bolts, or other suitable fasteners so that the pin housings  122 A,  122 B (and therefore the push-out pins  118 A,  118 B) are capable of being replaced in the event of inadvertent damage to either of the push-out pins  118 A,  118 B. The push-out pins  118 A,  118 B are co-axially aligned along an arm axis  126 , which extends in a direction of longitudinal extent of the pin removal arm  106 . The pin removal arm  106  further includes a wedge-shaped tip  130  disposed at the second end  114  of the pin removal arm  106 . The wedge-shaped tip  130  aids in guiding the pin removal arm  106  into the gap  340  of the toner cartridge  300  as the pin removal arm  106  moves along the x-direction  74 . In other words, the wedge-shaped tip  130  decreases the likelihood of inadvertent jamming between the pin removal arm  106  and the toner cartridge  300  during insertion of the pin removal arm  106  into the gap  340 . A recessed portion  134  is disposed adjacent the first end  110 , which also decreases the likelihood of inadvertent jamming between the pin removal arm  106  and the toner cartridge  300 . But in this case, the recessed portion  134  provides clearance when the pin removal arm  106  is already received in the gap  340  and the pin removal arm  106  moves in the y-direction  70  relative to the toner cartridge  300 . The recessed portion  134  includes a slimmer profile than the remainder of the pin removal arm  106  to provide clearance between portions of the toner cartridge  300  and the pin removal arm  106 . 
     In operation, the pin removal arm  106  is operable to remove (or at least partially displace) the pins  330 A,  330 B of the toner cartridge  300  in order to facilitate separation of the toner hopper  305  from the waste hopper  310 . In many cases, refurbishing of any print cartridge is simplified by complete or partial disassembly of the print cartridge. This holds true for the toner cartridge  300 , such that portions of the toner cartridge  300  are preferably disassembled to initiate a refurbishment process. As illustrated in  FIG. 5 , the pin removal arm  106  is in a default or “homed” position and the toner cartridge  300  is positioned within docking station  26 . In the homed position, the pin removal arm  106  is outside the vertical footprint of the toner cartridge  300  and the arm axis  126  is axially aligned with the gap  340  of the print cartridge  300 . As such, the pin axis  338  and the arm axis  126  are parallel (i.e., axially offset) relative to each other. The locking arm  34  is in the blocked position at this time (as shown in solid lines of  FIG. 1 ). 
     To initiate a pin removal sequence, the first auxiliary carrier frame  54  is actuated relative to the main carrier frame  46  via the second actuator  82  along the x-direction  74  towards the toner cartridge  300 . Since the second auxiliary carrier frame  58  is supported on the first auxiliary carrier frame  54 , the second auxiliary carrier frame  58  moves with first auxiliary carrier frame  54 . The first auxiliary carrier frame  54  is actuated a predetermined distance (set by the associated limit screws  102 ) that corresponds to the pin removal arm  106  being actuated through the gap  340  and positioned underneath waste hopper  310  of the toner cartridge  300 , as shown in  FIG. 6 . 
     With reference to  FIG. 7 , the pin removal arm  106  is moved in the y-direction  70  until the arm axis  126  of the pin removal arm  106  is co-axially aligned with the pin axis  338  of the toner cartridge  300 . To accomplish this, the main carrier frame  46  is actuated relative to the base  14  via the first actuator  78  along the y-direction  70  until the actuator  78  or main carrier frame  46  abuts the relevant limit screws  102 . When the pin removal arm  106  is moved in the y-direction  70 , the recessed portion  134  enables the pin removal arm  106  to avoid contact with a portion of the waste hopper  310 . 
     With reference to  FIG. 8 , the pin removal arm  106  is actuated along the arm axis  126  towards the pin  330 A via the second auxiliary carrier frame  58  and the third actuator  86 . The push-out pin  118 A of the pin removal arm  106  contacts the pin  330 A and at least partially displaces the pin  330 A from the connection joint  325 A. Subsequently, the pin removal arm  106  is actuated in the opposite direction along the arm axis  126  towards the pin  330 B, as shown in  FIG. 9 . To accomplish this, the pin removal arm  106  is actuated by the second auxiliary carrier frame  58  and the third actuator  86 . The push-out pin  118 B contacts the pin  330 B and at least partially displaces the pin  330 B from the connection joint  325 B. The amount which the push-out pins  118 A,  118 B displaces the pins  330 A,  330 B from the connection joint  325 A,  325 B is determined by the position of the limit screws  102  relative to the third actuator  86 . Specifically, the push-out pin  118 A stops displacing the pin  330 A when the piston rod  98  of the third actuator  86  abuts one of the limit screws  102 . Similarly, the push-out pin  118 B stops displacing the pin  330 B when the piston rod  98  of the third actuator  86  abuts another one of the limit screws  102 . Although the pins  330 A,  330 B are only partially displaced, in other embodiments, the pins  330 A,  330 B may alternatively be completely removed from the connection joints  325 A,  325 B. 
     At this point, the pin removal arm  106  is re-actuated along the arm axis  126  until the push-out pin  118 A merely touches (but does not exert a pushing force) the pin  330 A, corresponding to the piston rod  98  of the third actuator  86  abutting the limit screw  102 . As the piston rod  98  touches the limit screw  102 , the third actuator  86  now has a “zeroed” reference point that the third actuator  86  uses to properly reposition the pin removal arm  106  in-between the connection joints  325 A,  325 B, such that neither of the push-out pins  118 A,  118 B are in interference with the connection joints  325 A,  325 B. With the pin removal arm  106  properly positioned between the connection joints  325 A,  325 B, the main carrier frame  46  is now actuated in the y-direction via the first actuator  78  to realign the pin removal arm  106  with the gap  340  of the toner cartridge  300 . Finally, the first auxiliary carrier frame  54  is actuated along the x-direction via the second actuator  82  to remove the pin removal arm  106  from underneath the waste hopper  310  through the gap  340  until the pin removal arm  106  is in the homed position ( FIG. 5 ). The locking arm  34  is returned to the unblocking position ( FIG. 3 ), providing clearance for removal of the toner cartridge  300  from the docking station  26 . The pins  330 A,  330 B are now removed from the connection joints  325 A,  325 B by hand with the use of pliers or similar tool to avoid losing or misplacing the pins  330 A,  330 B. This way, the same pins  330 A,  330 B can be reused during reassembly of the toner cartridge  300 . 
     Thus, the invention provides, among other things, a system and method of remanufacturing a toner cartridge. Various features and advantages of the invention are set forth in the following claims.