Induction Heater Arch Core Vault Edge for Uniform Heating
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Solution Overview
Problem
The existing fixing devices in image forming apparatuses face inefficiencies due to variations in magnetic flux generation, leading to non-uniform heating of the heating roller, which results in faulty toner images on the recording medium, and increased manufacturing costs from precise cutting requirements for arch cores to ensure proper contact with side cores.
Innovation Solution
The use of arch cores with vault edge faces that contact the side cores over a consistent area, minimizing magnetic flux leakage and maintaining heating efficiency, regardless of the arch core's shape, thus eliminating the need for precise cutting and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If arch cores are used with planar edge faces to contact side cores, then magnetic flux can be guided effectively, but shrinkage during sintering causes variation in contact area leading to non-uniform heating
Solution Approach 1:
The arch cores are designed with a curved shape where the edge faces have an arc-shaped surface that contacts the side cores. This curvature allows the contact area to remain consistent even when shrinkage occurs during sintering, as the curved surface naturally accommodates dimensional variations while maintaining uniform contact pressure and magnetic flux distribution across all arch cores.
2Temperature
If precise cutting is performed on arch cores to ensure proper contact, then heating uniformity is maintained, but manufacturing complexity and costs increase
Solution Approach 1:
The curved edge face design eliminates the need for precise cutting operations. The arc-shaped contact surface is inherently formed during molding or sintering, and its geometry self-adjusts to maintain consistent contact area despite dimensional variations, thereby simplifying the manufacturing process while ensuring uniform heating.
Solution Approach 2:
The curved geometry of the arch cores enables them to self-adjust their contact area with the side cores based on their own dimensional characteristics. This self-adjusting mechanism compensates for shrinkage variations without requiring external intervention or additional processing steps, reducing manufacturing complexity.
3Ease of manufacture
If arch cores have varying contact areas with side cores, then manufacturing is simpler, but magnetic flux leaks causing non-uniform temperature distribution
Solution Approach 1:
The curved edge faces of the arch cores create a line contact or extended surface contact with the side cores, which maintains consistent magnetic flux guidance. The curvature ensures that even when contact area varies due to manufacturing tolerances, the magnetic flux path remains continuous and uniform, preventing energy loss through leakage.
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
This solution ensures uniform temperature distribution along the heating roller, improving fixing performance and reducing manufacturing expenses by maintaining heating efficiency and product quality without requiring additional cutting.
Implementation Method 1
the induction heater 24 generates a magnetic flux that generates an eddy current in proximity to a heating roller 23
Implementation Method 2
The eddy current causes the heating roller 23 including a heat generation layer to generate Joule heat by electric resistance of the heating roller 23
Implementation Method 3
the plurality of arch cores 42 and the side cores 44a and 44b contacting the arch cores can direct the magnetic flux toward the heating roller 23 while minimizing the leakage of magnetic flux
Data Source
AI summary
A fixing device includes an induction heater disposed opposite a heating rotary body and including a first side core disposed at one end of the induction heater, a second side core disposed at another end of the induction heater in a direction of rotation of the heating rotary body, and a plurality of arch cores arranged in an axial direction of the heating rotary body. Each arch core includes a first vault edge face disposed at one end of the arch core in the direction of rotation of the heating rotary body and contacting a planar face of the first side core and a second vault edge face disposed at another end of the arch core in the direction of rotation of the heating rotary body and contacting a planar face of the second side core.