Cushions for storing waste toner

Abstract

A cushion (104, 204, 304, 404, 504) for packaging a product includes an accommodation portion (106, 206, 306, 406, 506) shaped to receive a product, a cushion portion (107, 207, 307, 407, 507) adjacent to the accommodation portion to absorb impact, the cushion portion shaped to form an enclosure to store waste toner, and a connector to couple the cushion portion to a waste toner outlet (116, 122) of an image-forming apparatus (10).

Description

CUSHIONS FOR STORING WASTE TONERBACKGROUND

[0001] An image-forming apparatus using electrophotography prints an image on a recording medium by supplying toner to an electrostatic latent image formed on a photoreceptor to form a visible toner image on the photoreceptor. The visible toner image is then transferred to and fused on a recording medium. Toner may be supplied in a replaceable or refillable toner cartridge and ejected from the cartridge onto the photoreceptor. Waste toner may be supplied to a waste toner bottle for disposal or recycling.BRIEF DESCRIPTION OF THE DRAWINGS

[0002] FIGS. 1 A and IB are side views of an example of an image-forming apparatus.10003] FIG. 2A is a perspective view of an example of a packaged waste toner bottle.|0004] FIG. 2B and 2C are perspective views of examples of packaged toner cartridges.|0005] FIG. 3A is a side view of an example of a packaged toner cartridge.

[0006] FIG. 3B is a perspective view of the packaged toner cartridge of FIG. 3 A.

[0007] FIG. 3C is a cross-section side view of the packaged toner cartridge of FIG. 3A.

[0008] FIGS. 4A and 4B are cross-section perspective views of the packaged toner cartridge of FIG. 3 A.

[0009] FIGS. 5A and 5B are perspective views of an example of a packaged toner cartridge.|0010] FIG. 6A is a perspective view of a toner cartridge with a toner leakage prevention sheet.

[0011] FIG. 6B is a perspective view of a packaged toner cartridge with a toner cartridge packaging cushion and a toner leakage prevention sheet.[00121 FIG. 7A is a side view of an example of an image-forming apparatus.

[0013] FIG. 7B is a perspective view of the image-forming apparatus of FIG. 7A.

[0014] FIG. 8 A is a cross-section side view of the image-forming apparatus of FIG. 7A.

[0015] FIG. 8B is a cross-section perspective view of the image-forming apparatus of FIG. 7A.

[0016] FIG. 9A is a cross-section side view of the image-forming apparatus of FIG. 7A.

[0017] FIG. 9B is a cross-section perspective view of the image-forming apparatus of FIG. 7A.

[0018] FIGS 10A and 10B are cross-section perspective views of an example of a toner cartridge packaging cushion.10019] FIG. 11 A is a cross-section perspective view of an example of a toner cartridge packaging cushion.

[0020] FIGS. 1 IB and 11C are cross-section perspective views of an example of a toner cartridge packaging cushion.[0021 [ FIG. 12A is a side view of an example of a toner cartridge packaging cushion in a compressed state.

[0022] FIG. 12B is a perspective view of the toner cartridge packaging cushion of FIG. 12A in the compressed state.

[0023] FIG. 12C is a cross-section perspective view of the toner cartridge packaging cushion of FIG. 12A in the compressed state.|0024] FIG. 12D is a side view of the toner cartridge packaging cushion of FIG. 12A in an expanded state.

[0025] FIG. 12E is a perspective view of the toner cartridge packaging cushion of FIG. 12A in the expanded state.

[0026] FIG. 12F is a cross-section perspective view of the toner cartridge packaging cushion of FIG. 12A in the expanded state.

[0027] FIG. 13 A is a perspective view of an example of a packaged toner cartridge including the toner cartridge packaging cushion of FIG. 12A in the compressed state.

[0028] FIG. 13B is a cross-section perspective view of the toner cartridge packaging cushion of FIG. 12A installed in a print body in the expanded state.|0029] FIGS. 14A and 14B are perspective views of examples of a packaged toner cartridge.

[0030] FIG. 15A is a perspective view of an example of a toner cartridge packaging cushion.[0031 [ FIG. 15B is a perspective view of the toner cartridge packaging cushion of FIG. 15A coupled to a developer unit and a drum unit.[00321 FIG. 15C is a cross-section perspective view of the toner cartridge packaging cushion of FIG. 15A installed in a print body.

[0033] FIGS. 16A and 16B are perspective views of an example of a packaged toner cartridge.|0034] FIG. 16C is a perspective view of an example of a print body including multiple toner cartridges.

[0035] FIGS. 17A and 17B are perspective views of an example of a packaged toner cartridge.[0036[ FIG. 17C is a perspective view of a coupling of an example of a toner cartridge packaging cushion.

[0037] FIG. 17D is a perspective view of an example of a complementary coupling of a print body.

[0038] FIG. 18A is a side view of a toner cartridge packaging cushion coupled to a developer unit and a drum unit.

[0039] FIG. 18B is a perspective view of a toner cartridge packaging cushion of FIG. 18A coupled to the developer unit and the drum unit.

[0040] FIG. 18C is a side view of an example of the print body including four of the toner cartridge packaging cushions of FIG. 18 A.

[0041] FIG. 19A is a side view of an example of a packaged integrated toner cartridge.

[0042] FIG. 19B is a side view of an example of a packaged integrated toner cartridge.

[0043] FIG. 19C is a side view of the integrated toner cartridge of FIG. 19B arranged as installed in a print body.10044] FIG. 20 is a schematic view of an example of a method of using a toner cartridge packaging cushion.

[0045] It will be recognized that the figures are schematic representations for purposes of illustration. The figures are provided for the purpose of illustrating the implementations with the explicit understanding that the figures will not be used to limit the scope of the meaning of the claims.DETAILED DESCRIPTION

[0046] Waste toner bottles may be single-use or reusable containers that are inserted into a cavity in a print body of an image-forming apparatus to receive waste toner from the print body. The print body may include a photoreceptor drum unit with an auger configured to convey waste toner to a drum unit outlet that deposits the waste toner into an enclosure formed within the waste toner bottle. The print body may also include a developer unit that also includes an auger configured to convey waste toner to a developer outlet that deposits the waste toner into an enclosure formed within the waste toner bottle. When the enclosure is filled with waste toner, the waste toner bottle may be disposed of or emptied for reuse.

[0047] Toner cartridges and waste toner bottles may be shipped in boxes, for example, cardboard boxes. To reduce the likelihood of damage during shipping, the toner cartridges and waste toner bottles may be packed into packaging cushions before being inserted into the boxes. The packaging cushions may be made of paper or a polyethylene or polystyrene foam. Packaging and shipping each toner cartridge or waste toner bottle thus create waste in the form of boxes and packaging cushions, which may not be reused, as well as carbonemissions and pollution from manufacturing the toner cartridges, waste toner bottles, boxes, and shipping cushions and from shipping the boxes to the customer or retailer.

[0048] According to the examples described herein, a toner cartridge packing cushion may be reused as a waste toner bottle. This may eliminate the need for manufacturing and shipping dedicated waste toner bottles and allow for the reuse of the toner cartridge packing cushion before it is disposed of. For example, where supplying an image forming apparatus previously included shipping a waste toner bottle, waste toner bottle packaging cushions, a waste toner bottle box, a toner cartridge, toner cartridge packaging cushions, and a toner cartridge box, supplying the image forming apparatus may instead include shipping the toner cartridge, the toner cartridge packaging cushions, and the toner cartridge box. Further, where the waste toner bottle packaging cushions, the waste toner bottle box, the toner cartridge packaging cushions, and the toner cartridge box may previously have been disposed of after shipping, the waste toner bottle packaging cushions and the waste toner bottle box may not be manufactured and shipped, and the toner cartridge packaging cushions may be reused as waste toner bottles. Thus, the example toner cartridge packaging cushions described herein may reduce waste, carbon emissions, and other pollution caused by the use of dedicated waste toner bottles.

[0049] Referring to FIGS. 1 A and IB, an example of an image-forming apparatus 10 is shown. The image-forming apparatus 10 may include a print body 12, into which a toner cartridge 14 may be inserted. The toner cartridge 14 may supply toner to the print body 12. The print body may include a developer unit 16 and a drum unit 18. The developer unit 16 and the drum unit 18 may each extend into a cavity 20. As shown in FIG. IB, a waste toner bottle 22 may be inserted into the cavity 20. The waste toner bottle 22 may be shaped to occupy substantially all of the space of the cavity 20. The waste toner bottle 22 may define an enclosure 23 configured to store waste toner from the print body 12. The waste toner bottle 22 may include a first opening 24 through which an end of the drum unit 18 extends into the enclosure 23 and a second opening 26 through which an end of the developer unit 16 extends into the enclosure 23. The end of the drum unit 18 may define a drum unit outlet, and the end of the developer unit 16 may define a developer unit outlet. The drum unit outlet and the developer unit outlet may expel waste toner from the print body 12 into the enclosure 23 of the waste toner bottle 22. When the enclosure 23 is filled with toner, thewaste toner bottle 22 may be removed from the print body 12 and emptied or disposed of. The waste toner bottle 22 may be reused or replaced with a new waste toner bottle. In some cases, a waste toner bottle 22 may store the waste toner from one toner cartridge 14, while in other cases, a waste toner bottle 22 may be large enough to store waste toner from multiple toner cartridges installed and replaced in sequence.[0050| Referring now to FIG. 2A, an example of a packaged waste toner bottle 30 is shown. The packaged waste toner bottle 30 includes a waste toner bottle 22 packed in a waste toner bottle box 34 with waste toner bottle packaging cushions 35 coupled to the ends of the waste toner bottle 22. The packaged waste toner bottle 30 may include other packaging material, including a plastic bag surrounding the waste toner bottle 22 or additional cushioning to mitigate any impact forces on the waste toner bottle box 34. FIGS. 2B and 2C show examples of a packaged toner cartridge 40. The packaged toner cartridge 40 includes a toner cartridge 14 packed into a toner cartridge box 42 with toner cartridge packaging cushions 44 coupled to the ends of the toner cartridge 14. The example packaged toner cartridge 40 of FIG. 2B includes toner cartridge packaging cushions 44 made of paper or cardboard, and the example packaged toner cartridge 40 of FIG. 2B includes toner cartridge packaging cushions 44 made of plastic foam (e.g., polyethylene or polystyrene foam). The packaged toner cartridge 40 may include other packaging material, including a plastic bag surrounding the toner cartridge 14 or additional cushioning to mitigate any impact forces on the toner cartridge box 42.[00511 Referring now to FIGS. 3 A-3C, an example of a packaged toner cartridge 100 is shown. As shown in FIG. 3A, a toner cartridge 14 may be packed into a toner cartridge box 102 with toner cartridge packaging cushions 104 coupled to the ends of the toner cartridge 14, similar to the packaged toner cartridge 40 of FIGS. 2B and 2C. However, as shown in FIG. 3C, in addition to the accommodation portion 106 of the toner cartridge packaging cushion 104, which may be shaped to receive an end of the toner cartridge 14, the toner cartridge packaging cushion 104 may include a cushion portion 107 adjacent to the accommodation portion 106 and shaped to form an enclosure 108. After the toner cartridge 14 is shipped and unpacked from the toner cartridge box 102, the cushion portion 107 of the toner cartridge packaging cushion 104 may be used as a waste toner bottle, with the waste toner from the print body 12 being expelled into and contained within the enclosure 108.The toner cartridge packaging cushion 104 may be made from recycled paper or recycled plastic to further reduce the waste, carbon emissions, and other pollution associated with manufacturing packaging cushions from new material. The toner cartridge packaging cushion 104 may be manufactured using a molding operation or using a blowing operation. For example, the toner cartridge packaging cushion 104 may be manufactured from waste polyethylene terephthalate using a blow molding operation.

[0052] FIGS 4A-6B show features of the accommodation portion 106 of the toner cartridge packaging cushion 104. Referring to FIGS. 4A and 4B, section views of an example of a packaged toner cartridge 100 are shown. The toner cartridge 14 may be inserted into an opening 105 of the accommodation portion 106, such that the accommodation portion 106 surrounds an end of the toner cartridge 14. The toner cartridge 14 may include a modular jack 126 and a guide boss 128 extending from the end of the toner cartridge 14. The modular jack 126 may communicatively couple the toner cartridge to the print body 12, and the guide boss 128 may assist in guiding the toner cartridge 14 into the correct position within the print body 12 during installation. As shown in FIG. 4 A, the accommodation portion 106 of the toner cartridge packaging cushion 104 may include a modular jack protection structure 124, which may be a hollow cylindrical protrusion extending from the toner cartridge packaging cushion 104. When the toner cartridge 14 is inserted into the accommodation portion 106, the modular jack 126 may be inserted into and received and surrounded by the modular jack protection structure 124. The modular jack protection structure 124 may provide added protection to the modular jack 126 during the shipping and handling of the packaged toner cartridge 100. As shown in FIG. 4B, the accommodation portion 106 of the toner cartridge packaging cushion 104 may include a guide boss protection structure 130, which may be a hollow cylindrical protrusion extending from the toner cartridge packaging cushion 104. When the toner cartridge 14 is inserted into the accommodation portion 106, the guide boss 128 may be inserted into and surrounded by the guide boss protection structure 130. The guide boss protection structure 130 may provide added protection to the guide boss 128 during the shipping and handling of the packaged toner cartridge 100.[00531 Referring now to FIGS. 5 A and 5B, an example of a packaged toner cartridge 100 is shown. The toner cartridge packaging cushions 104 may include securing hooks 132 on atleast one side (e.g., on one, two, three, or all four sides) of the toner cartridge packaging cushions 104. The securing hooks 132 may hook onto and engage an edge 134 of the toner cartridge (or a portion or edge of another product) to couple and secure the toner cartridge packaging cushions 104 to the toner cartridge 14. As shown in FIG. 5B, the accommodation portion 106 of the toner cartridge packaging cushions 104 may include slots 133 on either side of the securing hook 132 to allow the hook 132 to deflect outward during the insertion and removal of the toner cartridge 14 from the toner cartridge packaging cushion 104. A toner cartridge packaging cushion 104 including securing hooks 132 may couple the toner cartridge packaging cushion 104 to the toner cartridge 14 more securely than a toner cartridge packaging cushion 104 that relies on an interference fit without a securing hook 132 to secure the toner cartridge packaging cushion 104 to the toner cartridge 14.|0054] Referring now to FIG. 6A, an example of a packaged toner cartridge 40 is shown. In the packaged toner cartridge 40, the toner cartridge 14 is packaged with a toner leakage prevention sheet 136, which is coupled to the toner cartridge 14 to cover a toner opening 138. The toner leakage prevention sheet 136 may be coupled to the toner cartridge 14 with an adhesive and may be removed by a user prior to installation of the toner cartridge 14 by pulling the toner leakage prevention sheet 136 away from the toner cartridge 14. If the toner leakage prevention sheet 136 is not removed from the toner cartridge 14 before installation of the toner cartridge 14 in a print body 12, an error will occur, and the imageforming apparatus 10 will not function properly. Because the toner leakage prevention sheet 136 is relatively small, a user may forget to remove it prior to installation of the toner cartridge. Referring now to FIG. 6B, an example of a packaged toner cartridge 100 is shown. In the packaged toner cartridge 100, a first end 139 of a toner leakage prevention sheet 140 may be coupled to the toner cartridge 14 covering the opening 138, and a second end 141 of the toner leakage prevention sheet 140 may be coupled to the toner cartridge packaging cushion 104. Thus, when the toner cartridge packaging cushion 104 is removed from the toner cartridge 14, the toner leakage prevention sheet 140 may remain coupled to the toner cartridge packaging cushion 104 and may be pulled away from the toner cartridge 14. Because the toner cartridge packaging cushion 104 is relatively large, a user may be less likely to attempt to install the toner cartridge 14 without removing the toner cartridge packaging cushion 104 or may be physically prevented from installing the toner cartridge 14without removing the toner cartridge packaging cushion 104. By removing the toner cartridge packaging cushion 104, the user will also remove the toner leakage prevention sheet 140, avoiding the potential error discussed above.

[0055] Referring now to FIGS. 7A and 7B, an example of an image-forming apparatus 10 is shown. The image-forming apparatus 10 may be similar to the image-forming apparatus 10 of FIGS 1A and IB. However, in the image-forming apparatus 10 of FIGS 4A and 4B, the waste toner bottle 22 has been replaced by the toner cartridge packaging cushions 104. One toner cartridge packaging cushion 104 (e.g., on the right as shown in FIGS 4 A and 4B) may be positioned to receive waste toner from the print body 12, and another toner cartridge packaging cushion 104 (e.g., on the right as shown in FIGS 4A and 4B) may be stored in the remaining portion of the cavity 20. When the toner cartridge packaging cushion 104 on the right is full of waste toner, it may be removed and replaced with the toner cartridge packaging cushion 104 on the left. In some examples, the toner cartridge packaging cushions 104 may instead be cushions configured to ship a different product, rather than a toner cartridge 14. For example, a cushion used to ship a replacement drum unit may be packed with cushions that include an accommodation portion configured to receive an end of the drum unit and a cushion portion including an enclosure configured to receive and store waste toner.10056] FIGS. 8A and 8B show section views of the image-forming apparatus 10 with the toner cartridge packaging cushion 104 positioned in the cavity 20. The section plane extends through a longitudinal axis of an auger 111 of a developer unit 110. The auger 111 conveys waste toner toward an end 114 of the developer unit 110, which extends through an opening 118 in the cushion portion 107 of the toner cartridge packaging cushion 104 into the enclosure 108. The end 114 of the developer unit 110 includes an outlet 116 through which the waste toner is expelled from the developer unit 110 into the enclosure 108. In some image-forming apparatuses, the toner may be mixed with developer material or carrier material when forming images. Waste developer material or waste carrier material may mix with the waste toner and be expelled via the outlet 116 into the enclosure 108.

[0057] FIGS. 9A and 9B show section views of the image-forming apparatus 10 with the toner cartridge packaging cushion 104 positioned in the cavity 20. The section plane extends through a longitudinal axis of an auger 113 of a drum unit 112. The auger 113conveys waste toner toward an end 120 of the drum unit 112, which extends through an opening 119 in the cushion portion 107 of the toner cartridge packaging cushion 104 into the enclosure 108. The end 120 of the drum unit 112 includes an outlet 122 through which the waste toner is expelled from the drum unit 112 into the enclosure 108. In some imageforming apparatuses, the toner may be mixed with developer material or carrier material when forming images. Waste developer material or waste carrier material may mix with the waste toner and be expelled via the outlet 122 into the enclosure 108. In some imageforming apparatuses, the developer unit may not include an outlet, and the cushion portion 107 may include only one opening for the end of the drum unit 112.[00581 Referring now to FIGS. 10A and 10B, an example of a toner cartridge packaging cushion 104 is shown. The toner cartridge packaging cushion 104 includes seals 142 positioned adjacent to the openings 118, 119. The ends 114, 120 of the developer unit 110 and the drum unit 112 may extend through the seals 142 and the respective openings 118, 119 into the enclosure 108 of the cushion portion 107 of the toner cartridge packaging cushion 104. The seals 142 may contain and maintain the expelled waste toner within the enclosure 108, both while the toner cartridge packaging cushion 104 is installed in the print body 12 and when the enclosure 108 is full of waste toner and the toner cartridge packaging cushion 104 is removed from the print body 12. The seals 142 may be polyurethane seals, the ends 114, 120 of the developer unit 110 and the drum unit 112 may be pushed through openings 143 in the seals 142 upon installation of the toner cartridge packaging cushion 104 in the print body 12. The seals 142 may tightly surround the ends 114, 120 of the developer unit 110 and the drum unit 112 so that waste toner remains sealed within the enclosure.When the toner cartridge packaging cushion 104 is removed from the print body 12, the openings 143 may reclose to seal the enclosure 108.[0059| Referring now to FIGS. 11 A-l 1C, examples of a toner cartridge packaging cushion 104 are shown. As discussed above, the ends 114, 120 of the developer unit 110 and the drum unit 112 deposit waste toner 144 into the enclosure 108 of the toner cartridge packaging cushion 104. The waste toner may accumulate at the bottom of the enclosure 108. The toner cartridge packaging cushion 104 may include a waste toner auger 146 configured to convey the waste toner 144 away from the ends 114, 120 of the developer unit 110 and the drum unit 112. An accumulation of waste toner 144 under the end 114 of thedeveloper unit 110 could reach the outlet 116 of the developer unit 110 and block additional waste toner from being expelled from the outlet 116. The waste toner auger 146 may move the waste toner away from the outlet 116 so that more waste toner may be expelled into and stored in the enclosure 108. The waste toner auger 146 may be coupled to a waste toner gear 148 positioned outside the enclosure 108. When the toner cartridge packaging cushion 104 is installed in the print body 12, the waste toner gear 148 may mesh with the drive gear 46 of the print body 12. The print body 12 may be configured to rotate the drive gear 46, and the drive gear 46 may drive the rotation of the waste toner gear 148, causing the rotation of the auger 146. As shown in FIGS 1 IB and 11C, the toner cartridge packaging cushion 104 may include a gear protection structure 150 to contain and protect the waste toner gear 148. The gear protection structure 150 may include an opening 149 to allow the drive gear 46 to mesh with the waste toner gear 148 upon insertion of the toner cartridge packaging cushion 104 into the print body 12.

[0060] Referring now to FIGS. 12C-12F, an example of a toner cartridge packaging cushion 204 is shown. The toner cartridge packaging cushion 204 may be substantially similar to the toner cartridge packaging cushion 104 except as shown and described herein. The toner cartridge packaging cushion 204 may include bellows 210 allowing the enclosure 208 formed in the cushion portion 207 to expand in volume. FIGS. 12A-12C show the toner cartridge packaging cushion 204 in a compressed state. FIGS 12D-12F show the toner cartridge packaging cushion 204 in an expanded state. The bellows 210 are positioned between the openings 218, 219 and their respective seals 242, between the opening 218 and an opening 244 through which a shaft of an auger (e.g., waste toner auger 146) may extend, and between the opening 244 and a wall of the enclosure 208 separating the accommodation portion 206 from the cushion portion 207. FIG. 13 A shows a packaged toner cartridge 200 including the toner cartridge packaging cushion 204 in the compressed state coupled to the toner cartridge 14. FIG. 13B shows the toner cartridge packaging cushion 204 in the expanded state installed in the print body 12. The bellows 210 allow for the toner cartridge packaging cushion 204 to be compressed during shipping, where a large enclosure 208 volume may not be needed to protect the toner cartridge 14 during shipping and handling. This may allow a relatively smaller toner cartridge 14 box to be used to ship the toner cartridge 14. The bellows 210 also allow for the toner cartridge packaging cushion 204 to expand to increase the volume of the enclosure 208. When the expanded toner cartridgepackaging cushion 204 is installed in the print body, the larger volume of the enclosure 108 may allow waste toner can be stored therein. Though not shown, the toner cartridge packaging cushion 204 may include a waste toner auger coupled to a waste toner gear (e.g., similar to the waste toner auger 146 and waste toner gear 148) configured to convey waste toner away from the outlets 116, 122.[00611 Referring now to FIGS. 14A and 14B, examples of a packaged toner cartridge 300 are shown. FIG. 14A shows the packaged toner cartridge 300 including three toner cartridge packaging cushions 304 positioned at three corners of the toner cartridge 14. FIG. 14A shows the packaged toner cartridge 300 including four toner cartridge packaging cushions 304 positioned at the four corners of the toner cartridge 14. The toner cartridge packaging cushions 304 may piece of similar to the toner cartridge packaging cushions 104, 204, except as shown and described herein. A toner cartridge packaging cushion 304 is shown in further detail in FIGS. 15A-15C. The toner cartridge packaging cushion 304 may include an accommodation portion 306 configured to receive a corner of the toner cartridge 14 and a cushion portion 307 defining an enclosure 308 configured to store waste toner. The volume of the enclosures 308 of three or four toner cartridge packaging cushions 304 may be larger and the volume of two of the toner cartridge packaging cushions 104. Thus, three or four toner cartridge packaging cushions 304 may collectively store more waste toner than two of the toner cartridge packaging cushions 104. As shown in FIGS. 15A-15C, the toner cartridge packaging cushion 304 may be installed in a print body 12 in substantially the same way as the toner cartridge packaging cushion 104. The toner cartridge packaging cushion 304 may include openings 318, 319 configured to receive the ends 114, 120 of the developer unit 110 and the drum unit 112. Though not shown, the toner cartridge packaging cushion 304 may include seals (e.g., similar to the seals 142) to seal the openings 318, 319. The toner cartridge packaging cushion 304 may include a waste toner auger 346 coupled to a waste toner gear 348, similar to the waste toner auger 146 and the waste toner gear 148, as well as a gear protection structure 350.10062] Referring now to FIGS. 16A, an example packaged toner cartridge 68 is shown. The packaged toner cartridge 68 may include a toner cartridge 70 with an end packaged in a toner cartridge packaging cushion 74. As shown in FIG. 16A, the toner cartridge packaging cushion 74 is a clamshell-style cushion with a hinge portion at one end. The packaged tonercartridge 68 further includes a handle 72. The handle 72 is configured to turn a coupling of the toner cartridge 70 upon installation of the toner cartridge 70 in a print body. Turning the coupling may rotate internal components of the toner cartridge 70 to agitate and break up any clumps in the toner within the toner cartridge 70 before the initial use of the toner cartridge 70. As shown in FIG. 16B, the ends of the toner cartridge 70 may be inserted into the toner cartridge packaging cushions, which may then be packed into a toner cartridge box 73. FIG. 16C shows an example of a print body 76 configured to receive multiple toner cartridges 70. For example, the print body may be configured to receive toner cartridges 70 containing toner of different colors. A user may install a toner cartridge 70 into the print body 76 and turn the handle 72 several times to agitate the toner in the toner cartridge 70. The user may then remove the handle 72 so that the print body 76 may operate using the toner in the toner cartridge 70. The print body 76 may include a cavity configured to receive a waste toner bottle or multiple waste toner bottles.

[0063] Referring now to FIGS. 17A and 17B, an example packaged toner cartridge 400 is shown. The packaged toner cartridge 400 may include a toner cartridge 70, which may be substantially similar to the toner cartridge packaging cushions 104, 204, 304, and two toner cartridge packaging cushions 404. The toner cartridge packaging cushions 404 may be substantially cylindrical in shape and may include an accommodation portion 406 configured to receive an end of the toner cartridge 404 during shipping and handling and a cushion portion 407 defining an enclosure 408 configured to receive and store waste toner. The toner cartridge packaging cushion 404 may include a coupling 460 in the accommodation portion 406, shown in further detail in FIG 17C. The coupling 460 may be substantially similar to a coupling of the handle 72 described above. The coupling 460 may interface with a complementary coupling 78 of the toner cartridge 70. During installation, a user may turn the toner cartridge packaging cushion 404 to rotate the complementary coupling 78, which may rotate internal components of the toner cartridge 70 to agitate the toner therein. Thus, the toner cartridge packaging cushion 404 may perform the functions of the handle 72 described above. After turning the toner cartridge packaging cushion 404 several times to agitate the toner, the toner cartridge packaging cushion 404 may be separated from the toner cartridge 70.

[0064] Referring now to FIGS. 18A and 18B, the toner cartridge packaging cushion 404 is shown coupled to portions of a print body 76 to capture and store waste toner from the developer unit 80 and the drum unit 82. Similar to the toner cartridge packaging cushion 104, the toner cartridge packaging cushion 404 may include openings 418, 419 through which ends of the developer unit 80 and the drum unit 82 extend. Waste toner may be expelled from outlets on the respective ends of the developer unit 80 and the drum unit 82 into the enclosure 408 of the toner cartridge packaging cushion 404. As shown in FIG. 18C, the cavity 79 of the print body 76 may be configured to receive multiple toner cartridge packaging cushions 404 to capture and store waste toner from the toner cartridges 70. For example, each toner cartridge packaging cushion 404 may be configured to capture toner from one of the toner cartridges 70.

[0065] Referring now to FIG. 19A, an example of a packaged toner cartridge 500 is shown. The packaged toner cartridge 500 may include an integrated toner cartridge 90 that includes a toner storage portion 91, a developer unit 92, and a drum unit 93 (e.g., an “all-on-one” toner cartridge) and toner cartridge packaging cushions 504. As shown in FIG. 19A, the toner cartridge packaging cushions 504 may include accommodation portions 506 configured to receive the ends of the integrated toner cartridge 90 and a cushion portion 507 defining an enclosure 508. The wall 509 separating the enclosure 508 from the accommodation portion 506 may include openings 510 through which an end 94 of the developer unit 92 and end 95 of the drum unit 93 may extend into the enclosure 508. The ends 94, 95 of the developer unit 92 and the drum unit 93 may include waste toner outlets (e.g., similar to the waste toner outlets 116, 122). To install the integrated toner cartridge 90, the second toner cartridge packaging cushion 504 (e.g., on the left as shown) may be removed from the integrated toner cartridge 90, while the first toner cartridge packaging cushion 504 (e.g., on the right as shown) may remain coupled to the integrated toner cartridge 90 when the integrated toner cartridge 90 is installed in a print body. When the enclosure 508 of the first toner cartridge packaging cushion 504 is full of waste toner, it may be removed and replaced by the second toner cartridge packaging cushion 504.

[0066] FIG. 19B shows another example of a packaged toner cartridge 500. In this example, the openings 510 in the toner cartridge packaging cushion 504 may be positioned at a different wall 511 of the cushion portion 507. The toner cartridge packaging cushion504 may include protection structures for the ends 94, 95 of the developer unit 92 and the drum unit 93 that protrude from the accommodation portion 506 and receive and surround the ends 94, 95. To install the integrated toner cartridge 90, the integrated toner cartridge 90 may be removed from the accommodation portion 506 and installed in a print body, and the toner cartridge packaging cushion 504 may be installed in the print body such that the ends 94, 95 of the developer unit 92 and the drum unit 93 extend through the openings 510. FIG. 19C shows the integrated toner cartridge 90 and the toner cartridge packaging cushion 504 as they would be installed in a print body.

[0067] FIG. 20 shows an example method 600 of using a packaging cushion (e.g., toner cartridge packaging cushions 104, 204, 304, 404, 504). A product, such as a toner cartridge, may be packed with a first end in an accommodation portion of the packaging cushion. At operation 602 of the method 600, the end of the product may be removed from the accommodation portion of the packaging cushion. For example, a user may hold on to the packaging cushion and pull the product away from the packaging cushion to remove the product from the accommodation portion. The product packed in the accommodation portion may be a toner cartridge. A first end of a toner leakage prevention sheet may be coupled to the packaging cushion and a second end of the toner leakage prevention sheet may be coupled to an outlet of the toner cartridge. When the toner cartridge is pulled away from the packaging cushion, the second end of the toner leakage prevention sheet may be decoupled from the outlet of the toner cartridge. At operation 604 of the method 600, a cushion portion of the packaging cushion may be coupled to a waste toner outlet of an image-forming apparatus such that the outlet may expel waste toner into the enclosure. The waste toner outlet may be formed in an end of a drum unit or an end of a developer unit of the image-forming apparatus. At operation 605 of the method 600, waste toner from the image-forming apparatus may be stored in an enclosure defined by the cushion portion. For example, waste toner may be ejected from the outlet of the drum unit or the developer unit into the enclosure. As discussed above, the product packed in the accommodation portion may be a toner cartridge. The method 600 may further include operation 601, at which, while the end of the toner cartridge is within the accommodation portion, the packaging cushion may be turned about a longitudinal axis of the toner cartridge to rotate a coupling of the toner cartridge. Rotating the toner cartridge may cause the agitation of toner in the toner cartridge and may break up any clumps of toner inside the toner cartridge. The method 600may further include operation 603, at which a first end of the cushion may be pulled in an opposite direction of a second end of the packaging cushion to expand a bellows to increase an inner volume of the enclosure of the packaging cushion. The method 600 may include more or fewer operations than those shown in FIG. 20, and the operations may be performed in any order except where an operation is dependent on the prior completion of another operation.

[0068] It should be noted that certain passages of this disclosure may reference terms such as “first” and “second” in connection with devices, surfaces or sides of devices, modes of operation, transmit chains, antennas, etc., for purposes of identifying or differentiating one from another or from others. These terms are not intended to merely relate entities (e.g., a first device and a second device) temporally or according to a sequence, although in some cases, these entities may include such a relationship. Nor do these terms limit the number of possible entities (e.g., devices) that may operate within a system or environment.|0069] While this specification contains specific implementation details, these should not be construed as limitations on the scope of what may be claimed but rather as descriptions of features specific to particular implementations. Certain features described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable sub-combination. Moreover, although features may be described as acting in certain combinations and even initially claimed as such, features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a subcombination.

[0070] As utilized herein with respect to structural features (e.g., to describe shape, size, orientation, direction, relative position, etc.), the terms “approximately,” “about,” “substantially,” and similar terms are meant to cover minor variations in structure that may result from, for example, the manufacturing or assembly process and are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications oralterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.

[0071] The term “coupled” and variations thereof, as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic.[00721 References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other examples, and that such variations are intended to be encompassed by the present disclosure.

[0073] With respect to the use of substantially any plural and / or singular terms herein, those having skill in the art can translate from the plural to the singular and / or from the singular to the plural as is appropriate to the context and / or application. The various singular / plural permutations may be expressly set forth herein for sake of clarity.

[0074] The foregoing description of illustrative examples has been presented for purposes of illustration and of description. It is not intended to be exhaustive or limiting with respect to the precise form disclosed, and modifications and variations are possible considering the above teachings or may be acquired from practice of the disclosed examples. It is intended that the scope of the claimed subject matter be defined by the claims appended hereto and their equivalents.

Claims

WHAT IS CLAIMED IS:

1. A cushion for packaging a product, the cushion comprising: an accommodation portion shaped to receive the product; a cushion portion adjacent to the accommodation portion to absorb impact, the cushion portion shaped to form an enclosure to store waste toner; and a connector to couple the cushion portion to a waste toner outlet of an image-forming apparatus.

2. The cushion of claim 1, wherein the accommodation portion comprises a hook to engage a portion of the product to couple the cushion to the product.

3. The cushion of claim 1, wherein the accommodation portion comprises a cylindrical protrusion to receive and protect a modular jack or a guide boss of the product.

4. The cushion of claim 1, wherein the cushion portion comprises an opening to receive an end of a drum unit or an end of a developer unit.

5. The cushion of claim 4, comprising a seal to seal the opening and maintain the waste toner in the enclosure.

6. The cushion of claim 4, comprising an auger configured to convey the waste toner within the enclosure away from the opening.

7. The cushion of claim 6, comprising a gear coupled to the auger and positioned outside the enclosure to mesh with a drive gear to drive the auger.

8. The cushion of claim 1, wherein the cushion portion comprises a bellows to expand the volume of the enclosure.

9. A method of using a packaging cushion comprising an accommodation portion to receive and protect an end of a product and a cushion portion adjacent the accommodation portion to absorb impact, the method comprising: removing the end of the product from the accommodation portion; coupling the cushion portion to a waste toner outlet of an image-forming apparatus; and storing waste toner from the image-forming apparatus in an enclosure defined by the cushion portion.

10. The method of claim 9, wherein the product is a toner cartridge, the method comprising, while the end of the toner cartridge is within the accommodation portion, turning the packaging cushion about a longitudinal axis of the toner cartridge to rotate a coupling of the toner cartridge, the rotation of the coupling causing agitation of toner in the toner cartridge.

11. The method of claim 9, comprising pulling a first end of the packaging cushion in an opposite direction of a second end of the packaging cushion to expand a bellows and increase an inner volume of the enclosure.

12. The method of claim 9, wherein the product is a toner cartridge, wherein: when the product is positioned within the accommodation portion, a first end of a toner leakage prevention sheet is coupled to an outlet of the toner cartridge, a second end of the toner leakage prevention sheet is coupled to the packaging cushion; and the first end of the toner leakage prevention sheet is decoupled from the outlet of the toner cartridge upon removal of the toner cartridge from the accommodation portion.

13. A toner cartridge comprising: a housing defining a toner storage portion and a waste toner outlet; and a cushion comprising:an accommodation portion shaped to receive an end of the housing; and a cushion portion adjacent to the accommodation portion to absorb impact, the cushion portion shaped to form an enclosure to store waste toner, the enclosure comprising an opening to receive the waste toner from the waste toner outlet.

14. The toner cartridge of claim 13, comprising a seal to seal the opening and maintain the waste toner in the enclosure.

15. The toner cartridge of claim 13, wherein the cushion portion comprises a bellows to expand the volume of the enclosure.

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