Method of remanufacturing corotrons

Information

  • Patent Grant
  • 6393235
  • Patent Number
    6,393,235
  • Date Filed
    Friday, August 3, 2001
    23 years ago
  • Date Issued
    Tuesday, May 21, 2002
    22 years ago
Abstract
A corona generator including a body and a first support secured to the body is provided. The corona generator also includes a second support secured to the body and spaced from the first support. The corona generator also includes an electrode mounted to the first support and to the second support.
Description




The present invention relates to a method and apparatus for charging a substrate in electrophotographic printing. More specifically, the invention relates to repairing a charging device.




In the well-known process of electrophotographic printing, the photoconductive member is electrostatically charged, and then exposed to a light pattern of an original image to selectively discharge the surface in accordance therewith. The resulting pattern of charged and discharged areas on the photoconductive member forms an electrostatic charge pattern, known as a latent image, conforming to the original image. The latent image is developed by contacting it with a finely divided electrostatically attractable powder known as “toner.” Toner is held on the image areas by the electrostatic charge on the photoreceptor surface. Thus, a toner image is produced in conformity with a light image of the original being reproduced. The toner image may then be transferred to a substrate or support member (e.g., paper), and the image affixed thereto to form a permanent record of the image to be reproduced. Subsequent to development, excess toner left on the photoconductive member is cleaned from the surface thereof. The process is useful for light lens copying from an original or printing electronically generated or stored originals such as with a raster output scanner (ROS), where a charged surface may be imagewise discharged in a variety of ways.




Various types of charging devices have been used to charge or precharge photoconductive insulating layers. In commercial use, for example, are various types of corona generating devices to which a high voltage of 5,000 to 8,000 volts may be applied to the corotron device thereby producing corona spray which imparts electrostatic charge to the surface of the photoreceptor. One particular device would take the form of a single corona wire strung between insulating end blocks mounted on either end of a channel or shield.




The single corotron wire is typically very delicate. The single corotron wire has a diameter of 0.001 inches and is made of a electrical conductive material, i.e., tungsten. Installing the single corona wire onto insulating end blocks of the corona generating device is very difficult. In particular, securing the ends of the single corona wire to the corona device is particularly difficult. Utilizing typical fasteners, such as bolts and screws to secure the wire, tends to overtighten the wire causing it to break. Use of adhesive to secure the wire to the corotron device is very time consuming in that the wire must be held in position as the adhesive dries. Welding of the wire to the corotron device is found to be particularly effective in that by welding, the wire is durably secured to the housing. Also, the welding process can occur very quickly providing for rapid and inexpensive assembly of the wire onto the housing.




Recently, to ease servicing of a copy machine or printing machine, customer replaceable units (CRUs) have been designed for easy removal from the copy machine by a copy machine operator. These customer replaceable units include those components which most quickly wear within the machine. For example, the customer replaceable unit may include the marking particles or toner as well as the photoreceptor, the cleaning blade, and the corotron wire. Alternatively, the CRU may include multiple CRUs. For example, the corotron may be included in a CRU having the photoreceptor, the cleaning blade, and the corotron wire. The corotron wire is typically permanently welded to the housing of the customer replaceable unit. To permit the assembly of the customer replaceable unit, typically, the housing of the CRU is made of more than one component. One of these components has the corotron wire welded thereto.




The CRUs are changed several times during the life of the copy machine. Recently, CRUs are being remanufactured rather than being replaced as a new unit. These CRUs are inspected and wear components, for example, the cleaning blade, corotron wire and photoreceptor, may require replacement. In those situations where the corotron wire must be replaced, since the wire is integrally welded to the portion of the frame of the CRU, the frame as well as the wire must be discarded during remanufacturing. This increases the cost of remanufacturing CRUs as well as requiring a portion of the frame be discarded or recycled.




The present invention is intended to eliminate at least some of the aforementioned problems.




The following disclosures may be relevant to various aspects of the present invention:




U.S. Pat. No. 5,140,367




Patentee: Olekinski, et al.




Issue Date: Aug. 18, 1992




U.S. Pat. No. 5,181,069




Patentee: Olekinski, et al.




Issue Date: Jan. 19, 1993




U.S. Pat. No. 4,754,305




Patentee: Fantuzzo et al.




Issue Date: Jun. 28, 1988




U.S. Pat. No. 4,627,701




Patentee: Onoda et al.




Issue Date: Dec. 9, 1986




U.S. Pat. No. 4,549,244




Patentee: Driessen




Issue Date: Oct. 22, 1985




U.S. Pat. No. 3,499,143




Patentee: Martin




Issue Date: Mar. 3, 1970




U.S. Pat. No. 5,140,367 discloses a method and apparatus for fitting a replacement corotron wire onto a corona wire cartridge. The assembly includes a pair of hook type terminals. The apparatus also includes a replacement wire having a loop at each end of the wire. One of the loops engages one hook terminal and the opposing loop connects to one end of a double hook ended coil spring. The opposing coil spring hook end is mounted on the opposing hook end terminal.




U.S. Pat. No. 5,181,069 discloses a method and apparatus for fitting a replacement corotron wire onto a corona wire cartridge. The assembly includes a pair of hook type terminals and rivets to mount the terminals onto a cartridge frame. The apparatus also includes a replacement wire having a loop at each end. One of the loop engages one hook terminal and the opposing loop connects to one end of a double hook ended coil spring. The opposing coil spring hook end is mounted on the opposing hook end terminal.




U.S. Pat. No. 754,305 discloses a corona discharge device which includes a throw away subassembly. The subassembly can be assembled into the printing machine. The subassembly includes a rectangularly shaped insulative frame and a tungsten wire. The subassembly cooperates with a generally U-shaped, conductive shield to form the corona discharge device.




U.S. Pat. No. 4,627,701 discloses a corona discharge device which includes a shield case, a discharging wire and block portions on which the discharging wire is mounted. The opposite ends of the wire are fixedly secured to the blocks by rivets.




U.S. Pat. No. 4,549,244 discloses a corona generating device including a plurality of separate parallel corona wires supported between insulating end block assemblies. The wires are preferably formed from a single U-shaped wire with a closed end portion wrapped around an arcuate insulating end post and an arcuate insulating end post in the second end block assembly around which the wire is wrapped.




U.S. Pat. No. 4,792,680 discloses a corona generating device including a corona wire. A supply of corona wire of indefinite length is mounted on the corona generating device for which one ore more runs of fresh wire can be periodically withdrawn with provision of releasably holding the wire under tension during periods of use.




SUMMARY OF THE INVENTION




In accordance with one aspect of the present invention, there is provided a corona generator including a body and a first support secured to the body. The corona generator also includes a second support secured to the body and spaced from the first support. The corona generator also includes an electrode mounted to the first support and to the second support.




In accordance with a further aspect of the present invention, there is provided a customer replaceable unit of the type having a corona generator for charging a surface. The corona generator includes a body, and a first support secured to the body. The corona generator also includes a second support secured to the body and spaced from the first support. The corona generator further includes an electrode mounted to the first support and to the second support.




In accordance with another aspect of the present invention, there is provided a printing machine of the type having a corona generating device for charging a surface. The corona generating device includes a body and a first support secured to the body. The corona generator also includes a second support secured to the body and spaced from the first support. The corona generator also includes an electrode mounted to the first support and to the second support.




In accordance with yet another aspect of the present invention, there is provided a method of remanufacturing a corona device having an electrode secured to a housing. The method includes the steps of removing the electrode from the housing, mounting a first support to the housing, mounting a second support to the housing, and attaching a new electrode to the first support and to the second support.











BRIEF DESCRIPTION OF THE DRAWINGS




The invention will be described in detail herein with reference to the following figures in which like reference numerals denote like elements and wherein:





FIG. 1

is a partial plan view of a wire charge frame with a support insert shown in phantom for mounting wires according to the present invention to remanufacturing corotron frames of customer replaceable units of an electrophotographic copy machine;





FIG. 1A

is a plan view of the support insert of

FIG. 1

for use with a wire charge frame to remanufacturing the corotron frames;





FIG. 1B

is an end view of the support insert of

FIG. 1A

;





FIG. 2

is a partial plan view of a wire charge frame of an original mounting configuration for mounting wires to the wire charge frame of a customer replaceable unit;





FIG. 3

is an elevational view of the support insert of

FIG. 1

for mounting wires to the corotron discharge device according to the present invention installed onto a customer replaceable unit of an electrophotographic copy machine;





FIG. 4

is an end elevational view of the customer replaceable unit of

FIG. 3

;





FIG. 5

is a sectional view of

FIG. 4

taken along the line


5





5


in the direction of the arrows;





FIG. 6

is a sectional view of

FIG. 3

taken along the line


6





6


in the direction of the arrows; and





FIG. 7

is a schematic elevational view of an illustrative electrophotographic printing machine incorporating the corona discharge device of the present invention therein.











While the present invention will be described in connection with a preferred embodiment thereof, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.




For a general understanding of the illustrative electrophotographic printing machine incorporating the features of the present invention therein, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to designate identical elements.

FIG. 7

schematically depicts the various components of an electrophotographic printing machine incorporating the corona discharge device of the present invention therein. Although the corona discharge device of the present invention is particularly well adapted for use in the illustrative printing machine, it will become evident that these corona discharge devices are equally well suited for use in a wide variety of uses and are not necessarily limited in their application to the particular embodiments shown herein.




Referring now to

FIG. 7

, the electrophotographic printing machine shown employs a photoconductive member in the form of a belt


16


, although photoreceptors in the form of a drum are also known, and may be substituted therefor. The belt


16


has a photoconductive surface deposited on a conductive substrate. Belt


16


moves in the direction of arrow


18


to advance successive portions thereof sequentially through the various processing stations disposed about the path of movement thereof. Motor


26


rotates belt


16


to advance belt


16


in the direction of arrow


18


. Belt


16


is coupled to motor


26


, by suitable means such as a drive.




Initially, successive portions of belt


16


pass through charging station A. At charging station A, a corona generating device, indicated generally by the reference numeral


30


, charges the belt


16


to a selectively high uniform electrical potential. The electrical potential is normally opposite in sign to the charge of the toner. Depending on the toner chemical composition, the potential may be positive or negative. Any suitable control, well known in the art, may be employed for controlling the corona generating device


30


.




A document


34


to be reproduced is placed on a platen


22


, located at imaging station B, where it is illuminated in a known manner by a light source such as a lamp


24


with a photo spectral output matching the photo spectral sensitivity of the photoconductor. The document thus exposed is imaged onto the belt


16


by a system of mirrors


25


and lens


27


, as shown. The optical image selectively discharges surface


28


of the belt


16


in an image configuration whereby an electrostatic latent image


32


of the original document is recorded on the belt


16


at the imaging station B.




At development station C, a development system or unit, indicated generally by the reference numeral


36


advances developer materials into contact with the electrostatic latent images. The developer unit


36


includes a device to advance developer material into contact with the latent image.




The developer unit


36


, in the direction of movement of belt


16


as indicated by arrow


18


, develops the charged image areas of the photoconductive surface


28


. This developer unit contains black developer, for example, material


44


having a triboelectric charge such that the black toner is urged towards charged areas of the latent image by the electrostatic field existing between the photoconductive surface and the electrically biased developer rolls in the developer unit which are connected to bias power supply


42


.




A sheet of support material


58


is moved into contact with the toner image at transfer station D. The sheet of support material


58


is advanced to transfer station D by conventional sheet feeding apparatus, not shown. Preferably, the sheet feeding apparatus includes a feed roll contacting the uppermost sheet of a stack of copy sheets. Feed rolls rotate so as to advance the uppermost sheet from the stack into a chute which directs the advancing sheet of support material into contact with the photoconductive surface of belt


16


in a timed sequence so that the toner powder image developed thereon contacts the advancing sheet of support material at transfer station D.




Transfer station D includes a corona generating device


60


which sprays ions of a suitable polarity onto the backside of sheet


58


. This attracts the toner powder image from the belt


16


to sheet


58


. After transfer, the sheet continues to move, in the direction of arrow


62


, onto a conveyor (not shown) which advances the sheet to fusing station E.




Fusing station E includes a fuser assembly, indicated generally by the reference numeral


64


, which permanently affixes the transferred powder image to sheet


58


. Preferably, fuser assembly


64


comprises a heated fuser roller


66


and a pressure roller


68


. Sheet


58


passes between fuser roller


66


and pressure roller


68


with the toner powder image contacting fuser roller


66


. In this manner, the toner powder image is permanently affixed to sheet


58


. After fusing, a chute, not shown, guides the advancing sheet


58


to a catch tray, also not shown, for subsequent removal from the printing machine by the operator. It will also be understood that other post-fusing operations can be included, for example, binding, inverting and returning the sheet for duplexing and the like.




After the sheet of support material is separated from the photoconductive surface of belt


16


, the residual toner particles carried by image and the non-image areas on the photoconductive surface are removed at cleaning station F. The cleaning station F includes a blade


74


.




It is believed that the foregoing description is sufficient for purposes of the present application to illustrate the general operation of an electrophotographic printing machine incorporating the development apparatus of the present invention therein.




Referring again to

FIG. 7

, the corona generating device


30


may include a single corona wire


80


. The wire


80


is strung between insulative end blocks of a remanufactured frame or housing


82


. Securing the wire


80


to the housing


82


is particularly difficult. The wire


80


typically has a very small diameter, say for example, 0.002 inches, and is made of an electrically conductive material, for example, tungsten. The use of fasteners to secure the wire


80


to the frame


82


causes the wire


80


to be overtightened and to break. The use of adhesive requires long cure times making that process expensive. Welding the wires


80


to the frame


82


is particularly advantageous in that a durable connection can be obtained at low cost.




Recently, to aid in the easy servicing of a copy machine or printing machine by an end user, and particularly for small inexpensive copiers, components that regularly wear during the life of the machine are packaged together in CRUs


140


(see FIGS.


3


and


4


). The CRUs typically are in the form of a housing which includes the photoreceptor


16


, cleaning blade


74


, the marking particles, and the corona generating device


30


. Alternatively the machine may include several CRUs, each of the CRU including a portion of the components to be replaced by the customer. For example, the CRU may include the photoreceptor


16


, cleaning blade


74


, and the corona generating device


30


.




According to the present invention, and referring to

FIGS. 3 and 4

, a customer replaceable unit


140


is shown utilizing the corona generating device


30


(see

FIG. 7

) having the wire mounting support insert the present invention.




To aid in the easy servicing of a copy machine or printing machine, a customer replaceable unit


140


as shown in

FIGS. 3 and 4

is typically designed to be easily removed from the copy machine. A typical example for the use of replacement of the customer replaceable unit


140


includes a support structure


144


of the copy machine which includes rails


146


to which housing


150


of the customer replaceable unit


140


matingly slide. The housing


150


preferably includes the wire charge frame


82


from which the wire


80


is supported.




Customer replaceable units


140


are changed several times during the life of the copy machine. The customer replaceable units


140


are recently being remanufactured rather than being replaced with new customer replaceable units.




The customer replaceable unit


140


includes the housing or cartridge


150


to which several components, namely those components found to require replacement on a more frequent basis within a copy machine or printing machine, are mounted. Typically, the customer replaceable unit


140


includes the photoreceptor belt


16


, the wire


80


and other items determined to wear at a significant rate. For example, the customer replaceable unit


140


may also include the blade


74


of the cleaning station F (see FIG.


7


).




Referring now to

FIG. 2

, an enlarged portion of an original wire charge frame is shown. Wire charge frame


182


represents a portion of an original wire charge frame as originally manufactured.




The wire charge frame


182


may be made of any suitable material, i.e., a metal or a plastic. Preferably, however, the wire charge frame


182


is made of a plastic, for example, polystyrene.




The corotron charge wire


80


is preferably strung from a first end


184


of the wire


80


, around approximately 1 to 4 revolutions of a first hitching post


186


, spaced from grid support


190


, and against first face


191


of wire guide


192


. From wire guide


192


, the wire


80


is strung around a wire tensioner in the form of an arcuate rail


193


. The arcuate rail


193


is preferably spring biased to provide for an accurately tensioned wire


80


. The wire


80


is then positioned against second face


189


of wire guide


192


. The wire


80


is then strung spaced from grid support


194


, wound around approximately 1 to 4 revolutions second hitching post


196


and then the wire


80


is held in tension at first end


184


and second end


200


of the wire


80


. The wire


80


intersects itself near first end


184


and second end


200


of the wire


80


. The wire


80


is preferably positioned at upper periphery of raised weld area


202


.




While the ends


184


and


200


are held in tension, the weld area


202


near the first and second ends


184


and


200


is contacted with a welding tool (not shown). The welding tool may be used in conjunction with any suitable plastic welder. An ultrasonic welder is particularly well suited for this application. The welder serves to raise the temperature of the wire charge frame to a temperature above the melting point of the wire charge frame, yet below the melting point of the wire


80


. Preferably, the weld area


202


protrudes above surface


204


of the wire charge frame. The weld area


202


melts and encases the wire


80


The weld area


202


may have any suitable shape, but preferably is in the form of a chevron or inverted V. When the weld area


202


is melted by the welding tool, the weld area


202


is fused to the wires


80


and the wires


80


are thereby permanently secured to the wire charge frame


182


.




When remanufacturing the CRU


140


(see FIGS.


3


and


4


), the wire


80


must often be replaced. Without the application of the present invention, the frame


182


would require replacement whenever the wire


80


was found to be worn or defective.




According to the present invention and referring again to

FIGS. 3 and 4

, a corotron wire assembly


210


is shown as part of the CRU


140


.




Referring now to

FIG. 6

, the corotron wire assembly


210


including the wire charge frame


82


is shown in greater detail as part of the frame


150


of the CRU


140


. The CRU


140


includes wiper cleaning blade


74


, the photoconductive belt


16


, wires


80


, as well as, a sump


209


for collecting spent toner


211


.




Referring now to

FIG. 5

, the corotron wire assembly


210


is shown in greater detail. The corotron wire assembly


210


as shown depicts a remanufactured corotron wire assembly


210


. The corotron wire assembly includes wire charge frame


82


. Wire charge frame


82


may be made of any suitable electrically non-conductive material, for example a plastic. Preferably, however, the wire charge frame


82


is made of a durable plastic, i.e. polystyrene.




The wire


80


is preferably strung between first insulating end block


212


and second insulating end block


214


. The end blocks


212


and


214


are preferably integral with the wire charge frame


82


. Preferably, the wire


80


is strung from a first end


216


of wire


80


, around approximately 1 to 4 revolutions of first hitching post


218


, spaced from grid support


219


, against first face


220


of first wire guide


221


, across the length of the wire charge frame


82


, against first face


222


of second wire guide


223


, spaced from grid support


219


, against but not wrapped around second hitching post


224


, around a wire tensioner in the form of an arcuate rail


225


, against but not wrapped around third hitching post


226


, spaced from grid support


219


, against second face


227


of second wire guide


223


, across the wire charge frame


82


, against second face


228


of first wire guide


221


, spaced from grid support


219


, around approximately 1 to 4 revolutions fourth hitching post


230


, and finally to second end


232


.




The first ends


216


and second ends


232


are held in tension with a tensioning device, preferably by spring bias against the arcuate rail


225


. Preferably, arcuate rail


225


is pivotally mounted on arm


234


. Preferably, the arcuate rail


225


is spring biased outwardly by spring


236


. Spring


236


may be any suitable durable spring having a proper spring force and may be chosen along with its position along the arm


234


to provide tensile force F suitable for proper operation of the wire


80


. The first end


216


and second end


232


of wire


80


are secured to the wire charge frame


82


by any suitable method, but preferably by welding. Preferably, the wire charge frame


82


includes a raised area or chevron


260


located in weld area


242


.




Referring now to

FIG. 1

, weld area


242


of the wire charge frame


82


is shown in greater detail. When a used wire charge frame


82


is remanufactured, the wire charge frame


82


includes an original welded area


246


including a melted plastic area which is raised above adjoining surface


244


of the wire charge frame


82


. The original weld area


246


is shown in phantom. When remanufacturing the wire charge frame


82


, the original weld area is machined away leaving a surface parallel to surface


244


. When machining away the original weld area


246


, the wires


80


embedded therein are removed as well.




The original weld area


246


may be removed by any suitable apparatus i.e., a milling machine including an end mill or a saw having a saw blade thereon. It should be appreciated that the surface around the original weld area may perform as well if it is slightly above or below the surface


244


.




In order to provide a material for welding the wire


80


to the frame


82


, preferably, additional material similar to the original material for the frame


82


, i.e. a plastic, for example, propylene, must be provided to permit the welding of a remanufactured wire charge frame


82


.




The additional plastic material in the original weld area may be attached to the frame


82


by any suitable method, for example, by adhesives, fasteners, or as shown in

FIG. 1

, include a pair of apertures


250


and


251


which are machined into the original frame


82


perpendicular to surface


244


within the weld area


246


. The apertures typically have a diameter D of approximately 1.5 millimeters. The apertures


250


are in the form of circular holes and the centerlines


252


and


254


thereof are positioned a distance X apart of approximately 8.0 millimeters.




Referring again to

FIG. 6

, the applicants have found that the frame


82


may be prepared by a simple three step process. First, one of the two holes, for example, first hole


250


, is drilled from


244


through to surface


248


. Since the polystyrene material is soft, burrs will form around first hole


250


at surface


248


. A step drill with an integral end mill is used to drill the second hole


251


. The step drill enters the frame


82


at surface


248


. After the tip of the drill exits surface


244


, the integral end mill removes the burr formed by the first drill around first hole


250


on surface


248


. Thirdly, a mill is used to remove the old weld, and the wire and the burrs around second hole


251


from the surface


244


. For example, the circular periphery of a cylindrical end mill may be passed over the welded area of surface


244


. A CNC machining center is suitable for this operation.




Referring now to

FIGS. 1A and 1B

, the chevron


260


for providing the weld for the wires


82


is shown in the form of chevron insert


260


. The chevron insert


260


provides the material to be welded or melted with the wire


80


to secure the wire to the remanufactured frame


82


.




Referring now to

FIG. 1A

, the chevron insert


260


may have any suitable shape. For example, the chevron may be in the form of an inverted V having a width W of approximately 2.0 millimeters. This shape is particularly well suited for welding, as this shape conforms to the angle of intersection of the wire


80


near the ends thereof and also conforms to the shape of the welding tool. The chevron may be in the shape of an inverted V having protrusions


256


and


258


extending from centerlines


262


and


264


, respectively, of the chevron insert


260


. The protrusions


256


and


258


have a diameter D


1


which is approximately the same as diameter D of the apertures


250


and


251


. The protrusions


256


and


258


extend a depth P preferably equal to the thickness of the wire charge frame


82


, for example, 2.0 millimeters. The protrusions


256


and


258


are respectively fitted into the apertures


250


and


251


of the frame


82


. When the welding tool (not shown) melts the chevron insert


260


, the protrusions melt and are welded to the frame


82


.




When a used remanufactured frame


82


is again milled or machined to remove the wires


80


, a similar process may be had utilizing a new chevron insert


260


. The chevron insert is shown in phantom in

FIG. 1

in position in the weld area


242


of frame


82


. Thereby, the frame


82


may be remanufactured several times. For example, applicants have found that the frame


82


may be easily remanufactured at least four times.




By providing a wire charge frame with a replaceable insert for mounting the wires to the corotron frame, a wire charge frame may be remanufactured rather than discarded.




By providing a wire charge frame having apertures which when mated with a chevron having pins, a remanufactured unit may be provided.




While this invention has been described in conjunction with various embodiments, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims.



Claims
  • 1. A method of remanufacturing a corona device comprising:removing an electrode from a housing; mounting a first support to the housing; mounting a second support to the housing; attaching a new electrode to the first support and to the second support; and welding the new electrode to the housing.
  • 2. The method of claim 1, wherein removing the electrode comprises machining the housing at the position where the electrode is secured to the housing.
  • 3. The method of claim 1 further comprising:machining mounting holes in the housing prior to mounting a first support; and wherein mounting a first support and mounting a second support comprises inserting protrusions extending from the first support and the second support into the holes in the housing.
  • 4. The method of claim 1 wherein attaching a new electrode comprises:stretching the new electrode between the first support and the second support; and welding the new electrode to the first support and to the second support.
  • 5. The method of claim 4 wherein the housing comprises at least one aperture therein; and wherein at least one of the first support and the second support comprise a protrusion extending at least partially into the at least one aperture.
  • 6. The method of claim 1 wherein at least one of the first support, second support, and the housing comprise a plastic.
  • 7. The method of claim 6 wherein at least one of the first support and the second support comprises a material having a melting temperature below a melting point of the new electrode.
  • 8. The method of claim 1 further comprising spacing the second support from said first support.
  • 9. The method of claim 1 wherein the corona device is part of a customer replaceable unit.
  • 10. The method of claim 1 further comprising providing a tensile force on the new electrode.
Parent Case Info

This application is a divisional of application Ser. No. 09/572,554, filed May 16, 2000, which is a divisional of application Ser. No. 08/753,458, filed Nov. 25, 1996, now U.S. Pat. No. 6,144,826.

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