Classifications

• • G—PHYSICS
  • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
  • G03G—ELECTROGRAPHY; ELECTROPHOTOGRAPHY; MAGNETOGRAPHY
  • G03G21/00—Arrangements not provided for by groups G03G13/00 - G03G19/00, e.g. cleaning, elimination of residual charge
  • G03G21/16—Mechanical means for facilitating the maintenance of the apparatus, e.g. modular arrangements
  • G03G21/18—Mechanical means for facilitating the maintenance of the apparatus, e.g. modular arrangements using a processing cartridge, whereby the process cartridge comprises at least two image processing means in a single unit
  • G03G21/1803—Arrangements or disposition of the complete process cartridge or parts thereof
  • G03G21/181—Manufacturing or assembling, recycling, reuse, transportation, packaging or storage
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
  • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
  • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/01—General aspects dealing with the joint area or with the area to be joined
  • B29C66/05—Particular design of joint configurations
  • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
  • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
  • B29C66/114—Single butt joints
  • B29C66/1142—Single butt to butt joints
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/01—General aspects dealing with the joint area or with the area to be joined
  • B29C66/05—Particular design of joint configurations
  • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
  • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
  • B29C66/124—Tongue and groove joints
  • B29C66/1244—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue
  • B29C66/12441—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue being a single wall
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
  • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
  • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
  • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
  • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
  • B29C66/541—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles a substantially flat extra element being placed between and clamped by the joined hollow-preforms
  • B29C66/5412—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles a substantially flat extra element being placed between and clamped by the joined hollow-preforms said substantially flat extra element being flexible, e.g. a membrane
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
  • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
  • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
  • B29C66/541—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles a substantially flat extra element being placed between and clamped by the joined hollow-preforms
  • B29C66/5414—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles a substantially flat extra element being placed between and clamped by the joined hollow-preforms said substantially flat extra element being rigid, e.g. a plate
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
  • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
  • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
  • B29C66/541—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles a substantially flat extra element being placed between and clamped by the joined hollow-preforms
  • B29C66/5416—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles a substantially flat extra element being placed between and clamped by the joined hollow-preforms said substantially flat extra element being perforated, e.g. a screen
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/80—General aspects of machine operations or constructions and parts thereof
  • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
  • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
  • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
  • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/80—General aspects of machine operations or constructions and parts thereof
  • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
  • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
  • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
  • B29C66/81463—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint
• • G—PHYSICS
  • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
  • G03G—ELECTROGRAPHY; ELECTROPHOTOGRAPHY; MAGNETOGRAPHY
  • G03G15/00—Apparatus for electrographic processes using a charge pattern
  • G03G15/06—Apparatus for electrographic processes using a charge pattern for developing
  • G03G15/08—Apparatus for electrographic processes using a charge pattern for developing using a solid developer, e.g. powder developer
  • G03G15/0822—Arrangements for preparing, mixing, supplying or dispensing developer
  • G03G15/0877—Arrangements for metering and dispensing developer from a developer cartridge into the development unit
• • G—PHYSICS
  • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
  • G03G—ELECTROGRAPHY; ELECTROPHOTOGRAPHY; MAGNETOGRAPHY
  • G03G15/00—Apparatus for electrographic processes using a charge pattern
  • G03G15/06—Apparatus for electrographic processes using a charge pattern for developing
  • G03G15/08—Apparatus for electrographic processes using a charge pattern for developing using a solid developer, e.g. powder developer
  • G03G15/0822—Arrangements for preparing, mixing, supplying or dispensing developer
  • G03G15/0877—Arrangements for metering and dispensing developer from a developer cartridge into the development unit
  • G03G15/0881—Sealing of developer cartridges
  • G03G15/0882—Sealing of developer cartridges by a peelable sealing film
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
  • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
  • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
  • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
  • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/80—General aspects of machine operations or constructions and parts thereof
  • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
  • B29C66/832—Reciprocating joining or pressing tools
  • B29C66/8322—Joining or pressing tools reciprocating along one axis
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/767—Printing equipment or accessories therefor
• • G—PHYSICS
  • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
  • G03G—ELECTROGRAPHY; ELECTROPHOTOGRAPHY; MAGNETOGRAPHY
  • G03G2215/00—Apparatus for electrophotographic processes
  • G03G2215/00987—Remanufacturing, i.e. reusing or recycling parts of the image forming apparatus

Definitions

• the present invention relates to improvements in the field of laser toner cartridge repair and manufacture in which a reassembled toner cartridge is resealed by ultrasonic welding resulting in improved product performance, increased production efficiency and decreased production cost.
• Toner or process cartridges for laser printing are engineered and manufactured to a high degree of precision necessary for proper operation and good printed image quality.
• Central to proper operation of a toner cartridge is the maintenance of alignment and orientation of its various components.
• Original equipment manufacturers achieve the rigidity necessary to maintain the alignment and orientation of components, in substantial part, by ultrasonically welding the sections of the toner or process cartridge together.
• the process of repair and reassembly of a toner cartridge requires that the cartridge be disassembled and that the hopper section of the cartridge which holds the toner be separated from the roller section which contains the developer roller and other components.
• precise alignment and orientation of performance critical components including particularly that between the developer roller and sealing blade and/or between the developer roller and developing blade may be lost.
• a primary drawback is that both metal clips and adhesive are consumables which increase production costs and cost of the final product.
• Another significant drawback is OSANGELES 108S 9vl that manual reassembly is quite labor intensive and is subject to human error and variation in quality. In the case of reassembly with adhesive or glue, there typically is a period of a few to several minutes for bonding to take place during which alignment must be maintained, and which increases production time and cost. Further, resealing with adhesive often fuses or bonds the sections together, rendering subsequent separation for additional remanufacturing cycles difficult or impossible.
• toner cartridges manufactured from new components by original equipment manufactures typically are sealed by ultrasonic welding, that technique has until now been unavailable for use in the repair or reassembly of toner cartridges.
• a primary impediment to the use of ultrasonic welding in the rejoining of the hopper section and roller section of a toner cartridge during reassembly has been either (1 ) that only a residual of the original energy element remains after the original manufacturing process or (2) that the energy director element is absence.
• An energy director element is a relatively small feature - typically in the form of a ridge or bump - which extends slightly above the surface of the surrounding area and contacts the surface to be welded.
• the energy director element is of the same material as the remainder of the plastic component and is formed in the mold in which the plastic component is created. During the ultrasonic welding process it is the energy director element which is first melted primarily as a result of the friction created between the two surfaces to be
• the present invention is directed to solving these problems by providing a reassembled toner cartridge and method of manufacture in which the hopper section and roller section are ultrasonically welded together without replacing the original energy director element, and without the need for or use of consumable components.
• the present invention improves the appearance and operational performance of toner cartridges which have been recycled, repaired and/or remanufactured from components including those from previously depleted toner cartridges, and provides a method whereby this may be accomplished.
• a further object of the present invention is to provide an improved method of rejoining subassemblies of previously depleted toner cartridges which permits the toner cartridge to be separated again at the location of the rejoining.
• Figure 1 A is a perspective view of a prior art toner cartridge in which the hopper section and the roller section are fastened together by clips.
• Figure 1 B is a perspective view of a prior art fastening clip.
• Figure 2A is a perspective view of a toner cartridge of the present invention in which the hopper section and the roller section are fastened together by point ultrasonic welding.
• Figure 2B is a perspective view of a toner cartridge of the present invention in which the hopper section and the roller section are fastened together by line ultrasonic welding.
• Figure 3A is partially disassembled perspective view of the hopper section, hopper section toner port perimeter seal, toner port ribbon seal and roller section assemblies of a toner cartridge that can be welded by the point welding method of the present invention.
• Figure 3B is partially disassembled perspective view of the hopper section, hopper section toner port perimeter seal, toner port ribbon seal and roller section assemblies of a toner cartridge that can be welded by the line welding method of the present invention.
• Figure 4A is a perspective view of an apparatus used in the ultrasonic welding step via point welding of the present invention.
• Figure 4B is a stylized perspective view of an apparatus which may be used in the ultrasonic welding step via line welding of the present invention.
• Figure 5 is a cross-sectional view through a portion of the Figure 2A assembly of a cartridge of the present invention at the location of an ultrasonic weld stylized to represent conformational change due to melting and pressure from the welding tip which is depicted in partial cross-section with a stylized tip face.
• Figure 6A is a cross-sectional view through a portion of the Figure 4B assembly of a representative process cartridge of the present invention.
• FIG. 6B is a cross-sectional view through a portion of the Figure 6A assembly of a representative process cartridge of the present invention at the location of an ultrasonic weld stylized to represent conformational change due to melting and pressure from the welding horn in the ultrasonic welding step.
• Figure 7A is a top perspective view of a toner cartridge of the present invention with a developer roller installed.
• Figure 7B is a top perspective view of another toner cartridge of the present invention with a developer roller installed.
• Figure 8 is a perspective view of a hopper section and a roller section of a representative process cartridge which depicts the mating surface of each section.
• Figure 9 is a partially disassembled perspective view of a hopper section, toner port ribbon seal and roller section assemblies of a process (toner) cartridge of an embodiment of the present invention.
• Figure 1 A is a perspective view of a prior art plastic toner cartridge (10) in which the hopper section (24) and the roller section (22) are fastened together by clips (12), a perspective view of one of which is separately shown in Figure 1 B.
• the remanufactured toner cartridge of the present invention (20) includes first peripheral lip (32) and second peripheral lip (34) of plastic roller section (22), and first peripheral lip (36) and second peripheral lip (38)(not shown) of plastic hopper section (24).
• Sealing blade (26) is disposed adjacent the developer roller (80) which is rotatably attached to roller supports (28) and (30) in roller section (22).
• Sealing blade (26) is conventionally fabricated of mylar sheet material having a thickness generally of the order of about 0.004 inch (0.01016 cm). It is highly preferred that the sealing blade (26) be essentially straight and uniformly positioned with respect to the surface of the developer roller (80) along its length. Variations in the degree of straightness or uniformity of positioning of sealing blade (26) with respect to the surface
• Figure 2B is depicts a toner cartridge in the present invention that is substantially similar to the one shown in Figure 2A.
• toner (20) includes longitudinal channel (31 ) having floor (29)(not shown).
• toner (20) includes components such as first peripheral lip (32) and second peripheral lip (34) of plastic roller section (22), and first peripheral lip (36) and second peripheral lip (38)(not shown) of plastic hopper section (24).
• Sealing blade (26) is disposed adjacent the developer roller (80) which is rotatably attached to roller supports (28) and (30) in roller section (22).
• Figure 3A is a partially disassembled perspective view of the hopper section (24), with the hopper section toner port perimeter seal (48), toner port ribbon seal (46) and roller section (22) assemblies of the toner cartridge (20) depicted in Figure 2A.
• the toner depicted in Figures 2A and 3A is suited for reassembly via point welding method.
• the toner cartridge (20) includes other components such as a waste hopper, developer roller, and other subassemblies which are not shown in Figures 2-9 for clarity.
• Hopper section (24) includes toner port seal cavity (42) in which is formed toner port (44).
• Sealing surface (43) of cavity (42) is adapted to accept and mates with adhesive surface (51) of toner port ribbon seal (46) and adhesive surface (52) of toner port perimeter seal (48), to close and seal toner port (44).
• Toner port ribbon seal (46) and toner port perimeter seal (48) are commercially available as an integral unit from OF. Technology (Goldseal).
• Perimeter seal (48) covers a larger area than does ribbon seal (46) and thus maintains a seal against toner leakage upon removal of the ribbon seal by the end user.
• hopper section (24) includes toner fill port (53) closed by hopper cap (50).
• Figure 3B is a partially disassembled perspective view of the hopper section (24), with the hopper section toner port perimeter seal (48), toner port ribbon seal (46) and roller section (22) assemblies of the toner cartridge (20) depicted in Figure 2B.
• the components of the toner shown in Figure 3B are substantially the same as depicted in Figure 3A, except the lips (37) and (39) are shown with longitudinal channels.
• Figure 9 is a partially disassembled perspective view of an embodiment of the present invention in which a toner port perimeter seal (48) is not needed, as the line welding technique employed is sufficient to act a seal.
• Toner port ribbon seal (46) is commercially available as a separate item.
• hopper section (24) includes first peripheral lip (36) having mating surface (37) and second peripheral lip (38) having mating surface (39). Lips (36) and (38) may or may not have a residual energy director element material left behind from the energy director used in original welding.
• Roller section (22) includes first peripheral lip (32) having mating surface (33) and second peripheral lip (34) having mating surface (35) (not shown). Lips (36) and (38) may or may not have a residual energy director element material left behind from the energy director used in original welding.
• cartridge clamping jig 60
• Clamping jig (60) is adapted to impose the preferred alignment and configuration on the cartridge assembly (20) during ultrasonic welding and bond curing. Two methods of welding exist in the present application and are discussed below.
• ultrasonic welding of sections (22) and (24) together is accomplished by a multi-head ultrasonic welding apparatus (70) such as is available from Branson Ultrasonics Corporation, Danbury, Connecticut. It is preferred
• the preferred locations for the ultrasonic welding of sections (22) and (24) is along peripheral lips (32), (34), (36) and (38) as is depicted schematically in Figures 2 and 4A. It has been determined that five ultrasonic spot welds, shown by welding tips (72), along each side of the remanufactured toner cartridge (20) is preferred to achieve the preferred alignment and configuration of the cartridge assembly, and to provide integrity against toner leakage. It will be understood by one skilled in the art that fewer or more than a total of five ultrasonic weld locations along each side of the toner cartridge (20) may be selected. It has further been determined that placement of the five ultrasonic welds (40) approximately uniformly along the toner cartridge lips as is depicted schematically in Figures 2A and 4A is preferred.
• an ultrasonic weld (40) is schematically depicted in cross-section to represent conformational change due to melting of the two cartridge sections (22) and (24) and pressure from titanium ultrasonic welding tip (72) which is depicted in partial cross-section with stylized tip face (74).
• the localized melting together of the two interfaced plastic surfaces in proximity to the energized titanium welding tip followed by maintenance of pressure during solidification of the melted material results in formation of an adhesive bond or weld.
• this method of welding can be performed without the need of energy director material element.
• the present invention also provides another ultrasonic welding method, namely line welding, as described with reference to Figure 4B.
• Ultrasonic welding of sections (22) and (24) together is accomplished by a dual-head ultrasonic welding horn (92) and ultrasonic welding apparatus (90) such as is available from Branson Ultrasonics Corporation, Danbury, Connecticut. It is provided that ultrasonic welding (and resealing) of the mating surfaces 33, 37 and 35, 39 of the cartridge sections take place simultaneously. However, it will be understood by one of ordinary skill in the art that the welding may take place sequentially.
• an ultrasonic weld (40) is schematically depicted in cross-section to represent conformational change due to melting of the two cartridge sections (22) and (24) and pressure from titanium ultrasonic welding horns (92) which are depicted in partial cross-section.
• welding horns (92) bear on channel floor (29) of longitudinal channel (31) to apply ultrasonic energy to the interface between mating surfaces (33) and (37) of section (22) and section (24), respectively.
• welding horns (92) bear on second peripheral lip (34) of roller section (22) to apply ultrasonic energy to the interface between mating surfaces (35) and (39) of section (22) and section (24), respectively.
• Figures 7A and 7B pertaining to the point and line methods of welding, respectively.
• the developer roller (80) is disposed and rotatingly mounted in the roller section (22).
• Figure 7A depicts five weld points (40) while
• Figure 7B depicts line weld via dotted lines (40) along each the lip of the toner.
• developer roller (80) which is essentially a right circular cylinder in geometry having a longitudinal axis (84), is disposed such that its longitudinal axis (84) extends along the length, or the greatest dimension, of roller section (22). Sealing
• LOSANGELES 108849vl blade (26) is disposed in roller section (22) such that the greatest dimension, or length, of sealing blade (26) also extends along the length, or the greatest dimension, of roller section (22), as has been previously described.
• the edge of sealing blade (26) proximate roller (80) defines sealing blade axis (82).
• developing blade (86) is also disposed in roller section (22) such that the greatest dimension of developing blade (86) extends along the length, or the greatest dimension, of roller section (22).
• the edge of developing blade (86) proximate roller (80) defines developing blade axis (88).
• reassembled toner cartridge (20) is maintained in preferred alignment and configuration by ultrasonic welds (40) such that longitudinal axis (84) of developer roller (80) and sealing blade axis (82) are essentially parallel along the extent or length of sealing blade (26), and the proximate surfaces of sealing blade (26) and roller (80) are maintained in substantially constant relation to each other over their mutual extent.
• reassembled toner cartridge (20) is maintained in preferred alignment and configuration by ultrasonic welds (40) (points in Figure 7A and lines in Figures 7B) such that longitudinal axis (84) of developer roller (80) and developing blade axis (88) are essentially parallel along the extent or length of developing blade (86), and the proximate surfaces of developing blade (86) and roller (80) are maintained in substantially constant relation to each other over their mutual extent.
• the depleted toner cartridge (20) is visually inspected for damage and whether it is suitable to be remanufactured. It is then partially disassembled to remove external components including the waste hopper, gear housing end plates, rollers, and hopper cap, etc. Next, any residual toner is removed and the cartridge is cleaned.
• roller section (22) is then separated from the hopper section (24) along the plane of the ultrasonic weld joining the two sections by a rotating blade which cleaves the ultrasonic weld. Thereafter the components are inspected for cleanliness and
• the toner port seal (46) and toner port perimeter seal (48) are next installed in hopper section.
• the toner port seal (46) can be installed alone in hopper section.
• the hopper section is then refilled with appropriate toner, and the hopper cap (50) is installed after which the hopper section is tested for toner leaks.
• the roller section (22) is then mated with the recharged hopper section (24) and the loose assembly is placed into a clamp jig which has been constructed to properly align and configure the particular type or model of cartridge being processed.
• the clamp jig is operated to impose the preferred alignment and configuration on the cartridge assembly.
• a multi-head (ten heads being preferred) ultrasonic welding apparatus simultaneously welds the roller section (22) and the hopper section (24) together at ten predetermined locations.
• a multi-head ultrasonic welding horn connected to an ultrasonic welding apparatus simultaneously welds the roller section (22) and the hopper section (24) together along both longitudinal edges at essentially the same locations as the original ultrasonic welds. If either case, this welding process requires approximately 1 second. Pressure on the weld points is maintained by the welding apparatus for approximately 10 seconds until the bond has cured, after which the resealed cartridge (20) is removed from the jig.
• components - new or repaired as necessary (developer roller, photoconductive drum, developer blades, etc.) - are installed in the roller section.
• the waste hopper is installed and the finished reassembled toner cartridge is subjected to post production quality control testing, after which it is packaged for shipment.

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• 2003
  • 2003-09-09 EP EP03794661A patent/EP1570317A4/de not_active Withdrawn
  • 2003-09-09 AU AU2003265985A patent/AU2003265985A1/en not_active Abandoned
  • 2003-09-09 WO PCT/US2003/028048 patent/WO2004023216A1/en not_active Ceased

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