Abstract: A re-rulable steel rule die frame is made from metal. Slots are cut in the metal die frame for receiving the blades of the steel rule. In one embodiment, the frame is a block of metal and the slots are cut such that the slots do not go completely through the frame. The blades are placed in the slots to form the desired cutting configuration. The edges of the blades opposite the cutting edges rest on the metal bottoms of the slots. The corners or ends of the blades are joined by welding, brazing or soldering without danger of burning the metal frame. In another embodiment, computer-directed laser beams cut precise slots in multiple layers of metal. The multiple layers are then joined together so the slots align, providing a precisely cut metal-framed steel rule die of a thickness able to withstand repeated stress. A modification of this embodiment allows the cut material to fall through the die. The desired shape is precisely cut in each frame layer, forming openings through each layer.

Abstract: A conversion kit and method for converting the doctor blade of a toner cartridge for an imaging machine to a spreader blade. The conversion kit comprises an elastic strip of material, such as nonconductive urethane, with adhesive on one side to attach the elastic strip to a surface of the doctor blade. An assembly jig is provided to hold the doctor blade in position while applying the elastic strip. The jig is designed and sized to act as a guide for ensuring the accurate positioning of the elastic strip on the doctor blade. The jig has a groove to grasp the bent-over portion of the doctor blade, and a raised edge adjacent the groove against which the elastic strip is placed. The conversion kit further comprises washers approximately the same thickness as the elastic strip. The washers are adhered to the surface of the doctor blade at each end adjacent the elastic strip and in alignment with the holes for the screws used to fasten the doctor blade to the toner cartridge.

Abstract: A stiffener which extends the life of a keeper blade used in toner cartridge assemblies to provide a seal with the photoreceptor drum between the waste toner hopper and the remainder of the cartridge assembly. The stiffener is attached along the length of the keeper blade and is also used to secure the keeper blade to the waste toner hopper. Two sides of the stiffener are provided with an adhesive, such as a two-sided tape. One side of the stiffener is attached to the keeper blade, and then the other side of the stiffener is used to secure the keeper blade to the waste toner hopper. The thickness of the stiffener is selected to set the distance between the keeper blade and the photoreceptor drum. The stiffener is made of a resilient material which may also be conductive. So the stiffener will not kink during cleaning or other maintenance and will conduct heat away from the keeper blade to prevent the blade from warping.

Abstract: A padding powder suspension or slurry and method for applying a padding powder for lubricating components of printing, copy and facsimile machines such as the photoreceptor drum, photoreceptor belt, wiper and doctor blade. The padding powder is comprised of a mica-group mineral or a mixture of a mica-group mineral and calcium stearate. The method comprises mixing the padding powder with a solvent, for example alcohol, to form a different substance. The mica-group mineral is inert so it does not dissolve in the alcohol. A suspension agent or surfactant may also be mixed with the padding powder and alcohol to keep the padding powder suspended in the alcohol for a longer period of time. The resulting suspension or slurry is then applied on the components. The suspension or slurry may easily be applied with brushes, spray devices, sponge materials or a soft cloth.

Abstract: A sleeve for the shaft section of a plastic drum axle used in toner cartridges for printing, copy and facsimile machines to rotatively support the photoreceptor drum. The sleeve is made of strong plastic or metal and is sized to snugly fit around the shaft section. Glue may be used to further secure the sleeve to the shaft section. The sleeve is slid onto the drum axle shaft section and abuts against the drum axle attach section. The sleeve has a length and an outside diameter which allow the sleeve to snugly fit in the gear piece of the photoreceptor drum, eliminating the clearance between the shaft section and gear piece passage. In this way the gear piece and photoreceptor drum are rotatively supported on the drum axle along nearly the entire length of the shaft section, preventing the photoreceptor drum from wobbling during operation and rotation.

Abstract: A dry toner composition for electrophotography includes a binder resin, a coloring agent and a mica-group mineral. The mica-group mineral provides the toner composition with lubricity and better flow capabilities. The mica-group mineral is wet-ground and may be coated with calcium stearate to reduce static electricity generated during operation of the printer, copier, or facsimile machine. The mica-group mineral and calcium stearate blend comprises ninety percent by weight or more of the mica-group mineral and ten percent by weight or less of the calcium stearate. The mica-group mineral or the mica-group mineral coated with calcium stearate makes up about zero-point-one to around fifteen percent by weight of the toner composition. The lubricant and flow agent formed by the mica-group mineral with or without the calcium stearate may be mixed into conventional dry toner as a post-additive.

Abstract: In one embodiment of the invention, the bore in the plastic bushing of a plastic gear attached to a photoreceptor drum in a toner cartridge is enlarged. A metal bushing is inserted within the plastic bushing and allows the gear to rotate around the drum shaft without wearing as quickly. The metal bushing, by pressing against the metal spring-clip contact, ensures the electrical ground connection between the drum and stationary drum shaft. In a second embodiment, the entire gear is manufactured from metal. A conductive joining material, metal prongs, or knurls on the outer surface of the metal bushing contact or scratch into the inner wall of the drum and provide the electrical ground connection between the inner wall of the photoreceptor drum and the drum shaft. On the nonconductive gear side of the drum, the hole in the cartridge wall which receives the gear shaft is lined with a bushing to prevent wear.

Abstract: In toner cartridge assemblies for use in copiers, printers and facsimile machines, a conductive coating is applied to the wiper and spreader blades. The wiper blade removes excess toner from the photo-sensitive photo-receptor drum and the spreader blade controls and adjusts the quantity of toner on the developing cylinder. The conductive coating is applied over the surfaces of the wiper and spreader blades which contact the drum and developing cylinder, respectively. The coating comprises polytetrafluoroethylene (TEFLON) made conductive by the addition of a conductive substance. The conductive coating reduces friction, minimizes toner attachment, and reduces warpage of the blades. The conductive coating eliminates static electricity within the cartridge assembly and, in the case of the wiper blade, eliminates the need for an erase lamp by providing a charge path away from the drum if the blade is grounded.

Abstract: An easily removable and reusable holding pin for securing together the sections of a toner cartridge assembly for use in imaging machines. The holding pin comprises a shank with a head structured to allow easy gripping of the pin by pulling tools. The head has a first portion wider than the shank which abuts against the wall of the assembly when the shank of the pin is inserted into the assembly to secure the sections together. The first portion separates the shank from a second portion of the head. The second portion is wider than the first portion of the head so it overhangs the first portion, providing a space between the second portion of the head and the assembly wall when the pin is installed in the cartridge assembly. The gripping parts of a tool may extend through this space to grip or otherwise contact the head of the pin, allowing the pin to be pulled from the assembly without damage to the pin or cartridge assembly.

Abstract: To allow a lathe to turn the photoreceptor drums, charge rollers and developer brushes of printers, copiers, and facsimile machines, a unitary component adapts the object so it can be held on the lathe and drives the object. The adapting portion includes a flexible material such as a hose or o-ring to snugly receive the end extension of the drum, roller or brush. The drive portion connects with the drive bolt of the lathe and spins the object. In a second embodiment, the drive and adapter portions are separate components. A bore in the drive bushing is lined with a short piece of hose or one or more o-rings and snugly receives a protrusion from the adapter unit. A third embodiment replaces the drive bushing with tail stock forced against the adapter unit by the drive bolt of the lathe. A bore in the adapter unit lined with a flexible hose or o-ring snugly receives the end of the tail stock.

Abstract: A spring-contact device which prevents the primary charge roller of a toner cartridge assembly from shifting back and forth and aids in providing the roller with an electrostatic charge. The device is made from a thin piece of electrically conductive material and comprises a long portion and a short portion bent from the long portion at an approximately right angle. The short portion has a hole in it for fitting over the hub on the charge roller mount in the toner cartridge assembly. The long portion presses against an endpost of the roller, maintaining a spring-contact. A spring-contact device is placed at each end of the charge roller such that the roller is held between the long portions of the spring-contact device by opposing forces.

Abstract: A toner delivering apparatus and method for supplying toner to the toner hoppers of toner cartridges used in printer, copier and facsimile machines. In one embodiment a balloon is filled with toner. A string or wire is wrapped aroound the center of the balloon. The balloon is sealed in a toner hopper, with the balloon attached to the inside walls of the hopper and a free end of the string or wire tied or otherwise secured to the toner lumping-prevention paddle. When the toner cartridge is loaded in the machine and operated, the paddle rotates, pulling and tightening the string or wire around the balloon. The balloon breaks or tears, releasing toner evenly along thelength of the toner hopper. In another embodiment, a plastic, cellophane-like material is used for the toner packaging. A pull-tear strip extends along the package and is also attached to the paddle. When the paddle rotates, the pull-tear strip is removed from the package, opening the package and distributing toner within the toner hopper.

Abstract: Components are disclosed which allow a powerful, variable speed lathe to turn the photoreceptor drums, charge rollers and developer brushes of printers, copiers, and facsimile machines. In one embodiment, adapter units fit over the cylindrical extensions on the ends of the drum. Two pieces of opposing tail stock support and hold the drum on the lathe by applying pressure against the adapter units. A drive bushing is attached to and rotates with the drive bolt of the lathe. The drive bushing has one or more drive pins which interact with the spoke-like members on the drum to turn or spin the drum and allow it to be cleaned, polished, coated or otherwise treated. In a second embodiment, a short length of hose is used to connect the adapter unit with the charge roller or developer brush. The drive pin of the drive bushing is received in a hole on the surface of the adapter unit facing the drive bushing. The roller or brush is turned on the lathe by having the drive bushing turn the adapter unit.

Abstract: A powdered chemical mixture for lubricating photoreceptors, wiper blades, doctor blades and slide seals used on dry toner printers, copiers, and facsimile machines. The dry powder comprises a mica group mineral wet-ground to attain cold, dry lubricity, resiliency and particle alignment. The wet-ground mica-group mineral may be coated by calcium stearate to increase lubricity and reduce static electricity from the photoreceptor and blades during operation of the machine. The optimum powder would be comprised of 99% by weight mica-group mineral and 1% by weight calcium stearate. Muscovite and phlogopite are mica-group minerals suggested for use in the lubricating powder. The calcium stearate could also be used with powdered lubricants other than mica to reduce static electricity during operation of the machines.

Abstract: An apparatus and method for providing a removable closure seal between the toner hopper and the toner feed roller compartment of a toner cartridge assembly used in printers, copy machines and facsimile machines. The seal prevents toner from leaking from the toner hopper into the feed roller compartment during shipping and handling. In one embodiment, the seal has a slotted seal insert placed over the passage between the hopper and roller compartment. A removable tape closes the slot. In another embodiment, a slotted seal insert is slid between grooves in the toner cartridge assembly into position between the hopper and feed roller compartment. The insert is attached to the cartridge assembly by glue, tape, or other adhesive. An insert tool is used to facillitate this attachment. A reusable, removable closure seal is slid between the grooves to close the slot. The closure seal may have a metal spine to increase its rigidity.

Abstract: A toner hopper seal-insert and slide-seal to provide for the shipping and transporting of a refilled toner cartridge. The seal-insert is comprised of two slotted rectangular strips or pieces of material. A middle piece or layer of a resilient two-sided foam tape is sandwiched between the two slotted pieces, holding them together such that their slots align. The tape is configured such that it also has a slot which is wider than the slots in the two outer pieces and open at one end, providing a channel for the slide-seal. The seal-insert is attached to the toner hopper of the toner cartridge, and the slide-seal is slid into or out of position in the seal-insert to seal or unseal the opening of the toner hopper, creating a reusable leakproof seal system. For ease of placing the seal-insert in the toner hopper, the ends of the outer pieces opposite the slot opening in the tape layer may be bent and fused together, then cut into a shape extending to a point.

Abstract: A method for modifying a conventional laser printer toner cartridge assembly so it may be used in a fax machine in place of more expensive cartridges specifically designed for the fax machine. The method comprises removing the cylinderical fitting stubs protruding from the toner hopper portion of the cartridge assembly by grinding or melting them off. Holes are melted in the indentations of the cartridge assembly at the location where the fax machine sensor operates. Clear, flat, thin plastic windows are attached over these holes to allow the light beam from the sensor to enter the toner hopper. An additional indentation is formed on the toner hopper portion of the cartridge assembly corresponding in location to fitting and aligning protrusions on the fax machine. This indentation is melted or pressed into the cartridge assembly casing and is made less sloppy and rough in appearance by applying a filler material over portions of the indentation.

Abstract: A strip of predetermined thickness and sufficient width is attached adjacent to the edges of spreader and wiper blades used in toner cartridge assemblies for printers, copiers and facsimile machines. The strip provides heat dissipation and distortion prevention characteristics to previously manufactured spreader and wiper blades. The strip is made of heat reflective material and might be a ductile metal such as aluminum or plastic which has elastomeric properties. The strip is attached to the blade by adhesive, metal plating, or by other methods. In one embodiment the strip is placed on the blade such that it is relatively flat. In another embodiment the strip is applied to the blade such that the strip forms an upstanding lip protruding angularly from the blade adjacent to the blade's edge. The strip or lip on the blade does not contact the roller on which toner is being spread or from which toner is being wiped.

Abstract: A toner hopper seal-insert and slide-seal to provide for the shipping and transporting of a re-filled toner cartridge used in printers and copying machines. The seal-insert is comprised of three slotted rectangular strips or pieces of material. A middle piece is sandwiched between two outer pieces. The slot in the middle piece is wider and open at one end, providing a channel for the slide-seal. The seal-insert is attached to the toner hopper of the toner cartridge, and the slide-seal is slid into or out of position in the seal-insert to seal or unseal the opening of the toner hopper, creating a reusable leakproof seal system. When the constriction in the end of the toner hopper is narrower than the width of the area being sealed, the slide-seal may be made narrow enough and the dimensions of the seal-insert slots may be made such that the slide-seal can be slid through the contriction and still seal the toner hopper opening to prevent the passage of toner.

Abstract: A toner hopper seal-insert and slide-seal to provide for the shipping and transporting of a refilled toner cartridge. The seal-insert is comprised of two slotted rectangular strips or pieces of material. A middle piece or layer of a resilient two-sided foam tape is sandwiched between the two slotted pieces, holding them together such that their slots align. The tape is configured such that it also has a slot which is wider than the slots in the two outer pieces and open at one end, providing a channel for the slide-seal. The seal-insert is attached to the toner hopper of the toner cartridge, and the slide-seal is slid into or out of position in the seal-insert to seal or unseal the opening of the toner hopper, creating a reusable leakproof seal system. For ease of placing the seal-insert in the toner hopper, the ends of the outer pieces opposite the slot openings in the tape layer may be bent and fused together, then cut into a shape extending to a point.