Booklet Forming With Sheet-Count Adaptive Toner Bonding
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Solution Overview
Problem
In existing image forming apparatuses, the region where the toner layer for bonding is formed is recessed, leading to potential deterioration in the quality of the sheet material bundle.
Innovation Solution
A booklet forming device that adjusts the thickness and pressure of the bonding layer based on the number of sheets being bonded, using a pressurizing member to melt the bonding toner and form a uniform bonding layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed heating and pressurizing condition is used for bonding sheets, then the bonding process is simple, but the bonding layer thickness becomes non-uniform when the number of sheets varies, causing recessed regions
Solution Approach 1:
The patent applies dynamics by making the operation conditions of the bonding unit variable rather than fixed. The heating temperature and pressurizing force are dynamically adjusted based on the number of sheets to be bonded. This allows the system to adapt to different sheet quantities, ensuring uniform bonding layer thickness regardless of whether 10 or 50 sheets are being bonded, thereby preventing recessed regions while maintaining reasonable system complexity.
Solution Approach 2:
The patent changes the parameters of the bonding process (heating temperature and pressurizing force) based on the number of sheets. When more sheets are bonded, the heating temperature and pressurizing force are increased proportionally. This parameter adjustment ensures that the bonding layer thickness remains uniform across different sheet quantities, resolving the technical contradiction between manufacturing precision and operation simplicity.
2Manufacturing precision
If the number of sheets to be bonded is not predetermined, then the device is versatile, but the bonding quality becomes inconsistent
Solution Approach 1:
The system maintains versatility by accepting any number of sheets while ensuring consistent bonding quality through dynamic adjustment. The bonding unit automatically adapts its heating and pressurizing parameters based on the actual number of sheets present, allowing the device to handle variable sheet quantities without compromising bonding quality consistency.
Solution Approach 2:
The patent implements a feedback mechanism where the number of sheets is detected (via sheet detection means), and this information feeds back to control the heating and pressurizing conditions. This closed-loop control ensures that bonding quality remains consistent regardless of whether 5 or 50 sheets are being bonded, resolving the contradiction between versatility and quality consistency.
3Strength
If high pressure is applied to bond many sheets, then bonding strength is sufficient, but the bonding layer becomes too thin causing recessed regions
Solution Approach 1:
The patent changes both pressure and temperature parameters in proportion to the number of sheets. When more sheets are bonded, both the pressurizing force and heating temperature are increased. This coordinated parameter adjustment ensures that sufficient bonding strength is achieved while maintaining adequate bonding layer thickness, preventing the formation of recessed regions that would occur with high pressure alone.
Solution Approach 2:
The bonding process utilizes the composite effect of both thermal energy and mechanical pressure acting together on the toner layer. By combining heating and pressurizing in proportional relationship to sheet quantity, the system achieves both sufficient bonding strength and adequate layer thickness, resolving the contradiction between strength and thickness.
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
Ensures consistent bonding quality across varying numbers of sheets, preventing recessed toner regions and enhancing the overall product quality.
Implementation Method 1
heating and pressurizing the sheets, supported by the sheet support portion, by the pressurizing member to melt the toner for bonding
Implementation Method 2
melt the toner for bonding
Implementation Method 3
pressurizing the sheets, supported by the sheet support portion, by the pressurizing member
Data Source
AI summary
A booklet forming device includes a sheet support portion, and a bonding unit including a pressurizing member and configured to form a bonding layer. In a case of forming a first booklet including a first number of sheets, the bonding unit is operated under a first operation condition so that a thickness of the bonding layer positioned closest to the pressurizing member in the first booklet becomes a first thickness. In a case of forming a second booklet including a second number of sheets more than the first number of sheets, the bonding unit is operated under a second operation condition different from the first operation condition so that the thickness of the bonding layer positioned closest to the pressurizing member in the second booklet becomes a second thickness larger than the first thickness.