Toner Cartridge End Cap Modification to Prevent Seal Removal
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Solution Overview
Problem
Toner cartridges with internal seals that are automatically removed upon installation in a printer face issues during post testing, leading to undesirable toner leakage during packaging and shipment, as the seals are removed during the testing process.
Innovation Solution
Modifying the toner cartridge's drive mechanism by disabling at least one gear of the mechanism that operates the toner seal removal, allowing for post testing without disturbing the internal toner seal, and then re-enabling the mechanism for normal operation when the cartridge is installed in a printer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If post testing is performed on remanufactured toner cartridges, then printing defects can be detected, but the internal toner seal is removed causing toner leakage during packaging and shipment
Solution Approach 1:
The cartridge is divided into two functional states: a test configuration where the drive mechanism is disabled to preserve the seal, and an operational configuration where the drive mechanism is enabled to remove the seal. This segmentation allows the same cartridge to serve different purposes without compromising either function.
Solution Approach 2:
The drive mechanism is made dynamically controllable through a modification device that can disable/enable it. During post testing, the modification device disables the drive mechanism to keep the seal intact. After testing, the seal is manually removed and the drive mechanism is re-enabled for normal operation. This dynamic control resolves the contradiction between needing the seal intact for testing and needing it removed for operation.
2Ease of operation
If the internal toner seal is removed during post testing, then printing defects can be detected, but toner leaks during packaging and shipment
Solution Approach 1:
The modification device is pre-configured to disable the drive mechanism before post testing begins. This preliminary action ensures that when the cartridge is installed in the printer for testing, the seal remains intact because the drive mechanism cannot operate. After testing completes, the seal is manually removed and the drive mechanism is re-enabled, restoring full functionality.
3Productivity
If the drive mechanism is enabled during post testing, then the toner seal removal mechanism operates, but toner leaks during packaging and shipment
Solution Approach 1:
The modification device extracts or disables the drive mechanism's functionality during post testing. By taking out the operational capability of the drive mechanism, the seal cannot be automatically removed during testing. After testing, the seal is manually removed and the drive mechanism's functionality is restored, allowing automated seal removal in future operations.
Data Source
AI summary
A method of remanufacturing a toner cartridge includes installing a modified end cap in which a portion of a drive assembly for an internal toner seal removal mechanism has been disabled. With the modified end cap installed, the toner cartridge may be post tested without removing the internal toner seal. When the post test is complete the modified end cap is removed and a non-modified end cap with a functional drive assembly is installed in its place.