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 a gear side end portion of a waste bin assembly of the toner cartridge. The altered toner cartridge is installable then installable in a different printer.

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 physical structures from an end portion of the toner cartridge. The converted cartridge may then be used in other printers. 
       SUMMARY 
       [0007]    A method of modifying an imaging process cartridge, the imaging process cartridge installable in a first color imaging device and not installable in a second color 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 hollow surfaced fin, a lower hollow surfaced fin, a solid surfaced protrusion and ribs extending between said upper and lower hollow surfaced fins and said protrusion, all mounted on a lower vertical surface, said lower vertical surface extending from a first end to a mid point of said gear side end portion, wherein said upper and lower hollow surfaced fins and said protrusion extend from said first end towards said midpoint, and removing said lower hollow surfaced fin and a section of said ribs such that a channel is created, said channel extending from said first end to said midpoint and about in between said upper hollow surfaced fin and said protrusion, said modified imaging process cartridge is installable in said second color imaging device. 
         [0008]    A method of modifying an imaging process cartridge, the imaging process cartridge installable in a first color imaging device and not installable in a second color 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 hollow surfaced fin, a lower hollow surfaced fin, a solid surfaced protrusion and ribs having a first height, said ribs extending between said lower hollow surfaced fin and said protrusion, all mounted on a lower vertical surface, said lower vertical surface extending from a first end to a mid point of said gear side end portion, wherein said upper hollow surfaced fins and said protrusion extend from said first end towards said midpoint and said lower hollow surfaced fin is located at or about said midpoint and comprises a right wall a left wall and a lower wall, removing said left wall and said lower wall, and reducing in height said right wall and said protrusion such that said right wall and said protrusion are about equal to said first height, said modified imaging process cartridge is installable in said second color imaging device. 
         [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 front perspective view of a fully assembled prior art HP3600/3800 toner cartridge. 
           [0011]      FIG. 2  shows an exploded view of a waste bin assembly of the HP3600/3800 toner cartridge with the toner hoper removed. 
           [0012]      FIG. 3A  shows a side perspective view of a gear side end portion the waste bin assembly of the HP3600/3800 toner cartridge. 
           [0013]      FIG. 3B  shows a side view of the end portion of  FIG. 3A . 
           [0014]      FIG. 3C  shows a front view of the end portion of  FIG. 3A . 
           [0015]      FIG. 4A  shows a side perspective view of a modified gear side end portion of a waste bin assembly of the HP3600/3800 in accordance with one embodiment of the present invention. 
           [0016]      FIG. 4B  shows a side view of the end portion of  FIG. 4A . 
           [0017]      FIG. 4C  shows a front view of the end portion of  FIG. 4A . 
           [0018]      FIG. 5A  shows a side perspective view of a gear side end portion of a prior art HP3000 waste bin assembly. 
           [0019]      FIG. 5B  shows a side view of the end portion of  FIG. 5A . 
           [0020]      FIG. 5C  shows a front view of the end portion of  FIG. 5A . 
           [0021]      FIG. 6A  shows a side perspective view of a modified gear side end portion of a waste bin assembly of the HP3000 in accordance with one embodiment of the present invention. 
           [0022]      FIG. 6B  shows a side view of the end portion of  FIG. 6A . 
           [0023]      FIG. 6C  shows a front view of the end portion of  FIG. 6A . 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    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. 
         [0025]    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. 
         [0026]    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 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. 
         [0027]    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 used in the HP3600 color laser printer is exactly the same cartridge used in the HP3800 color laser printer. The other HP3600 color toner cartridges are physically identical to the HP3800 color toner cartridges with the exception of an electronic identification chip. Even though the cartridges fit interchangeably in either printer, an error message may be displayed by the printer if an HP3600 cyan toner cartridge is installed in an HP3800 color laser printer. 
         [0028]    In subsequent sections, the present invention is discussed with reference to the HP3600 toner cartridge as an illustrative example. However, since the HP3600 cartridges and the HP3800 cartridges are physically identical, it is intended that the inventive concepts as explained as they relate to the HP3600 cartridges also apply to the HP3800 toner cartridges as well. 
         [0029]    The HP3600 toner cartridges may have exactly the same internal components and even use the same toner as the toner cartridges used in the HP3000 color laser printer. The two cartridge types may be quite similar physically. The only physical differentiating feature between the two styles of cartridges is the keys and their locations on an end portion of their respective waste bin assemblies. 
         [0030]    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. 
         [0031]    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 for use one type of printer to be useable in another type of printer. 
         [0032]    As is discussed in greater detail in subsequent sections, a toner cartridge used in the HP3600 color laser printer is not physically compatible in the HP3000 color laser printer due to keying differences between the cartridges. Similarly, toner cartridges used in the HP3000 color laser printer are not compatible for use in the HP3600 color laser printer. 
         [0033]      FIG. 1  shows a front perspective view of a prior art toner cartridge  100  used in the HP3600 color laser printer. The cartridge  100  may be installed in any of the toner cartridge locations within the HP3600 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 gear side end portion  200  as well as a contact side end portion  130 . During the remanufacturing process, the hopper assembly  110  and the waste bin assembly  120  are separated. 
         [0034]      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  215  is inserted into the OPC drum  214  allowing the OPC drum  214  to rotate. A PCR  216  (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). 
         [0035]    The HP3600 color toner cartridges are not compatible in the HP3000 color laser printers due to physical differences in the waste bin assembly gear side end portion  200 .  FIG. 3A  displays a side perspective view of the waste bin assembly gear side end portion  200  for the HP3600 color laser printer. During the typical refurbishment process, the waste bin assembly gear side end portion  200  is not removed from the cartridge  100  because the gear side end portion  200  is molded together with the waste bin assembly  120 . In the supporting figures the gear side end portion  200  is shown separated merely for illustrative purposes. 
         [0036]    As can be seen in  FIG. 3A , the gear side end portion  200  has an upper hollow surfaced fin  310  and a lower hollow surfaced fin  320  located at a first end  304  of a first lower vertical surface  302 .  FIG. 3B  displays a side view of the gear side end portion  200  and  FIG. 3C  shows a cut away front view of the gear side end portion  200  with the gear side end portion  200  cut at the axis A-A. 
         [0037]    The upper and lower hollow surfaced fins  310 ,  320  extend perpendicularly away from the lower vertical surface  302  (shown as a dashed line in  FIG. 3C ) and are about the same height h 1 . The two hollow surfaced fins  310 ,  320  align with corresponding recesses located in the printer cartridge location within the HP3600 color laser printer. Typically, the height h 1  is about ½″ (1.3 cm). 
         [0038]    The lower vertical surface  302  extends laterally from the first end  304  to about a mid point  306  of the gear side end portion  200 . Mounted on the lower vertical surface  302  below the lower hollow surfaced fin  320  is a solid surfaced protrusion  330  which extends a height h 2  above the lower surface  302 . In the embodiment shown in  FIG. 3C , the height is typically 0.2″ (4.7 mm) 
         [0039]    Extending from about the midpoint  306  away from the first end  304  towards a second end  335  is an upper vertical surface  308 . Latticed all throughout the lower vertical surface  302  and part of the upper vertical surface  308  are ribs  360 . The ribs  360  connect the upper and lower hollow surfaced fins  310 ,  320 , and the solid surfaced protrusion  330 . The height of the ribs  360  varies. The ribs  360  located at or about the mid point  306  are roughly the same height h 1  as lower hollow surfaced fin  320 . However, there is one fin  380  at the midpoint  306 , parallel to axis A-A, which is between the upper hollow surfaced fin  310  and the lower hollow surfaced fin  320  that has a height h 3  (about 0.3″ or 7.6 mm) and is shown as shaded in  FIG. 3C . Ribs  360  near the upper and lower hollow surfaced fins  310 ,  320  protrude about a 0.2″ (4.7 mm) away from the lower vertical surface  302 . 
         [0040]    Altering an image process cartridge having the characteristics of toner cartridges used in the HP3600 color laser printer to allow it to fit in an HP3000 color laser printer requires altering the physical characteristics of the gear side end portion  200 .  FIGS. 4A-C  display views of an altered gear side end portion  200 ′ in accordance with one embodiment of the present invention. As can be seen in the side perspective view of  FIG. 4A , the lower hollow surfaced fin  320  has been removed. In addition, the ribs  360  between the upper hollow surfaced fin  310  and the solid surfaced protrusion  330  have been reduced in height to a height h 5 . A channel of length l 1  extends between the upper hollow surfaced fin  310  and the solid surfaced protrusion  330  from the first end  304  through a portion of the upper vertical surface  308 . The shaded structures as displayed in  FIG. 4B  show where the physical modifications are made. 
         [0041]    As shown in the embodiment of  FIG. 4C , the modified ribs are reduced in size. The height h 5  of the modified ribs and lower hollow surfaced fin  320  may protrude about less than 0.1″ or 2.54 mm above the lower vertical surface  302 . In another embodiment, the modified lower hollow surfaced fin  320  and ribs may be removed completely, with nothing protruding away from the lower vertical surface  302 . 
         [0042]    One way to modify the gear side end portion  200  is to use a hack saw, file, band saw, jig saw, Rotozip™, Dremmel™ or other similar tool. Although not recommended, the channel may be created by melting ribs and the lower hollow surfaced fin  320 . Once the channel has been created, a file or other type of tool may be used in order to smooth out any rough surfaces left over from the modification process. 
         [0043]    In yet another embodiment, an HP3000 toner cartridge is modified in order to allow it to fit in an HP3600 color laser printer. As mentioned previously, the gear side end portions of the two cartridges are slightly different.  FIGS. 5A-C  display an unaltered gear side end portion  500  of an HP3000 toner cartridge. The front view of  FIG. 5C  shows a cutaway view of the gear side end portion  500  as cut away on axis B-B ( FIG. 5B ) which is about at a midpoint  506 . 
         [0044]    As can be seen in  FIGS. 5A-C , the gear side end portion  500  is similar to the gear side end portion  200  of  FIGS. 3A-C . Gear side end portion  500  has an upper hollow surfaced fin  510  protruding away from a lower vertical surface  502 , extending from a first edge  504  towards the midpoint  506 . The gear side end portion  500  also has a lower hollow surfaced fin  520  that has a lower side  521 , a left side  522 , an upper side  523  and a right side  524 . The location of lower hollow surfaced fin  520  is different than lower hollow surfaced fin  320 . Lower hollow surfaced fin  520  is still below the upper hollow surfaced fin  510  and mounted on lower vertical surface  502 , but it is located at or near the midpoint  506 . The height h 7  of the lower hollow surfaced fin  520  is about equal to the height of the upper hollow surfaced fin  510 , which is about ½″ (12.7 mm). 
         [0045]    Mounted on the lower vertical surface  502 , at first edge  504  and below the upper hollow surfaced fin  510  is also solid surfaced protrusion  530 . Latticed between the upper hollow surfaced fin  510  and the solid surfaced protrusion  530  are ribs  560  extending away from the lower vertical surface  502 . The ribs vary in height with some ribs having a height about equal to the height of the upper hollow surfaced protrusion h 7 . Below the upper hollow surfaced fin  510  the ribs have a height h 6  of about 0.1″ (2.5 mm). Those ribs parallel with the solid surfaced protrusion  530  have a height h 4  of about 0.3″ (7.6 mm). 
         [0046]    In accordance with another embodiment of the present invention, the gear side end portion  500  may be modified to allow the modified toner cartridge to be able to fit inside an HP3600 color laser printer. A modified gear side portion  500 ′ is displayed in  FIGS. 6A-C . The first step in converting the gear side end portion  500  includes reducing the height of the solid surfaced protrusion shown as shaded areas of  FIG. 6B . The altered protrusion has a height about or equal to the height h 4  of the adjacent ribs  560  ( FIG. 6C ) 
         [0047]    In addition to removing a section of the solid surfaced protrusion  530 , most of the lower hollow surfaced fin  520  is also removed. As shown in  FIG. 6B , the lower wall  521  and the left wall  522  are completely removed. The modified right wall  524 ′ has a height of h 4  and no modifications are performed on the upper wall  523 . 
         [0048]    As previously discussed, the modifications to the gear side end portion  500  may involve using a hack saw, band saw, jig saw, Rotozip™, Dremmel™ or other similar tool. Although not recommended, the modifications may be accomplished by melting the associated structures. 
         [0049]    Within the toner cartridge, 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 altered toner cartridge to function properly in its new location or printer. 
         [0050]    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.