Abstract: An agitator blade and toner cartridge that enables a higher capacity of toner while lowering the load exerted by the print engine motor as toner is agitated. This allows for greater efficiency at low toner levels as the blade is brought closer to the inner wall of the cartridge toner tank. The blade consists of an axially directed axle shaft having a plurality of rigid, radially directed ribs A plurality of cross bar members are mounted between each pair of ribs. Each cross bar includes axially extended, rib-engaging wings. The wings are mounted so that the cross bars are generally prevented from passing between the ribs when the cross bars are driven by the ribs in the normal direction of agitator rotation. The toner cartridge can include a volume extension member that is sized to fit within the empty space of a corresponding print engine.

Abstract: This invention provides a timing wheel assembly for controlling the timing of toner cartridge operation that is fixedly attached to a shaft of a toner tank agitator and that is operatively connected to a drive gear of a toner cartridge mounted coaxially on the shaft with the timing wheel movable between a first stop and a second stop relative to the drive gear to define rotational “dwell” range having a predetermined arcuate distance with a pair of springs of differing strengths. The first spring, of a first strength (first spring constant) biases the timing wheel against the first stop and the second spring of a second strength (second spring constant) is engaged by the timing wheel at higher resistance levels. In this manner, the first spring ensures that an appropriate dwell and snapback motion occurs at lower toner levels and the second spring (in combination with the first) provides heavier resistance and stronger rotational resistance/earlier snapback at higher toner levels.

Abstract: This invention provides an agitator blade and toner cartridge employing such an agitator blade that enables a higher capacity of toner while lowering the load exerted by the print engine motor as toner is agitated. This blade and cartridge also allows for greater efficiency at low toner levels as the blade is brought closer to the inner wall of the cartridge toner tank. The blade consists of an axially directed axle shaft having a plurality of rigid, radially directed ribs that extend to a location proximate to the inner wall of the tank. A plurality of cross bar members are mounted between each pair of ribs. Each cross bar includes axially extended, rib-engaging wings. The wings are mounted so that the cross bars are generally prevented from passing between the ribs when the cross bars are driven by the ribs in the normal direction of agitator rotation.

Abstract: A metering blade confronts the developer roller of a toner cartridge with a working face and associated upstream corner that is accurately controlled with respect to the developer roller to achieve a desired gap therebetween. More particularly, the quality of toner metering is determined through an appropriate technique and the angle of the bottom working face and working corner is varied using appropriate computer-controlled machining techniques to adjust the location of the corner with respect to the radial centerline of the roller at all points along the axial direction. In an illustrative embodiment, the blade's working face is formed to create a setback that is compound angle in two orthogonal directions. This compound angle reorients the upstream corner of the working face to compensate for irregular metering and electrostatic differences across the roller surface, particularly where toner is greater on one side of the roller than the other, opposing side.

Abstract: An improved developer roll magnet for a toner cartridge provides a strip of magnetic material that extends axially along a surface of the developer roll magnet located coaxially within a developer roll sleeve. The strip of magnetic material can be seated within a groove in the magnet and can extend radially outwardly above the surface of the magnet. The strip is generally adhered to the magnet by mutual magnetic attraction and can be made adjustable to move toward and away from the developer roll sleeve. The strip is typically located adjacent a nip formed between the developer roll sleeve and the image transfer drum of the cartridge to provide enhanced toner release for greater print yield and quality.

Abstract: A seal for a printer toner cartridge, and a method for employing the seal is provided. The seal provides a flexible thin sheet material that can be folded to form two plies. The thin sheet material defines a seal that is wrapped around the developer roller of the toner cartridge so that a portion of the sheet material extends outwardly from the toner cartridge and can include a pull tab. The sheet material fills gaps formed between the developer roller and a doctor blade and also between the developer roller and a toner application roller. An additional layer is preferably provided to the seal, and joined adjacent the pull tab. It passes through a gap defined between the application roller and another roller, such as a primary charge roller. In addition a compressible strip may be provided between layers of the seal for enhancing the seal. By sealing these gaps, a positive barrier to toner expulsion is created.