Drive Gear Assembly Separation in Laser Printer Toner Cartridge Remanufacturing

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Solution Overview

Problem

The existing remanufacturing processes for laser toner cartridges face challenges in maintaining print quality due to the degradation of the photosensitive drum's coating, leading to the need for frequent replacement of the aluminum cylinder, while the drive gear assembly remains undegraded and potentially reusable.

Innovation Solution

A method and apparatus are developed to separate and reuse the drive gear assembly from the photosensitive drum assembly, allowing for the replacement of the worn-out aluminum cylinder and re-coupling with a new one, utilizing pneumatic clamp and piston apparatuses to avoid damaging the gear teeth, and crimping tools to secure the new cylinder.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the aluminum cylinder is replaced to improve print quality, then the print quality is improved, but the manufacturing cost and complexity increase

Engineering Contradiction:

Improveprint qualityVSAvoidremanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent divides the drum assembly into separable components: the aluminum cylinder with photoconductive coating and the drive gear assembly. This segmentation allows the aluminum cylinder to be replaced for coating renewal while the drive gear assembly is preserved and reused, simplifying the remanufacturing process by enabling modular replacement of only the worn component rather than the entire assembly

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies the discarding and recovering principle by discarding only the exhausted aluminum cylinder with degraded coating while recovering and reusing the drive gear assembly. This selective replacement reduces manufacturing costs and complexity compared to replacing the entire drum assembly, while still achieving the goal of restored print quality

Inventive Principle:

Principle #34Discarding and recovering

2Ease of manufacture

If the drive gear assembly is removed using excessive force, then the separation is achieved, but the gear teeth are damaged

Engineering Contradiction:

Improvedrive gear separationVSAvoidgear teeth integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent introduces a pneumatic clamp as an intermediary device that provides controlled, uniform force distribution during the separation process. The clamp gradually releases the crimping pressure holding the drive gear assembly to the aluminum cylinder, allowing clean separation without concentrating excessive force on specific gear teeth, thus preventing damage while achieving successful separation

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces traditional mechanical force-based separation methods with a pneumatic system. The pneumatic clamp uses controlled air pressure to gradually release the crimping force, providing a more precise and controllable separation process that avoids the gear tooth damage associated with sudden mechanical force application

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If the aluminum cylinder is replaced frequently to maintain print quality, then the print quality is maintained, but the waste and cost increase

Engineering Contradiction:

Improveprint qualityVSAvoidmaterial waste

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

By segmenting the drum assembly into replaceable aluminum cylinder and reusable drive gear assembly, the patent enables selective replacement of only the consumable component (aluminum cylinder with coating) while preserving the durable component (drive gear assembly). This reduces material waste by keeping functional parts in service beyond the life of the photoconductive coating

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements discarding and recovering by discarding only the exhausted aluminum cylinder while recovering the drive gear assembly for reuse in remanufactured drums. This approach reduces material waste and remanufacturing costs by utilizing the durable gear assembly multiple times across different aluminum cylinder replacements

Inventive Principle:

Principle #34Discarding and recovering

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach reduces waste, lowers remanufacturing costs, and improves print quality by extending the life of the drive gear assembly and maintaining the integrity of the helical gear teeth, enabling the reuse of the drive gear assembly with a new drum-cylinder.

Implementation Method 1

utilizing pneumatic clamp and piston apparatuses to avoid damaging the gear teeth

Methodology Applied

Scientific EffectPneumatic pressure: Pressure Increase

Implementation Method 2

crimping tools to secure the new cylinder

Methodology Applied

Scientific EffectCrimping: Mechanical Force

Data Source

PatentUS9146533B2Process for installing original drive gear on a laser printer toner cartridge drum

Publication Date: 2015.09.29 CLOVER IMAGING GRP LLC

AI summary

A method is disclosed. The method provides an assembly that contains a first drum-cylinder having an inner periphery surface and a drive gear assembly, wherein a portion of the drive gear assembly is in contact with the inner periphery surface, separates the drive gear assembly from the first drum-cylinder, inserts the portion of the drive gear assembly into a second drum-cylinder, and couples the drive gear assembly to the second drum-cylinder.