Fixing Film With Variable Conductive Layer Thickness
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Solution Overview
Problem
Existing fixing devices in image forming apparatuses, such as copiers and printers, face inefficiencies in heat generation and energy consumption due to the uniform heat distribution and high warm-up times, particularly in the electrode and heat generation portions of films used in these devices.
Innovation Solution
A film with a cylindrical shape featuring a base layer, an electrode portion at one end, and a heat generation portion in the middle, both made of a conductive layer with varying thickness and surface area, where the electrode portion has a larger thickness and surface area than the heat generation portion, allowing for controlled Joule heating and reduced heat generation in non-essential areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the conductive layer has uniform thickness throughout the film, then the manufacturing process is simple, but the heat distribution is uniform causing excessive heat in electrode portions and increased energy consumption
Solution Approach 1:
The conductive layer is designed with non-uniform thickness: thicker in electrode portions (first and second electrode portions) and thinner in the heat generation portion. This local variation optimizes heat distribution by reducing heat generation in electrode areas while maintaining effective heating in the intended region, thereby lowering overall energy consumption without requiring complex multi-layer structures
2Loss of time
If the film generates high heat quickly, then the warm-up time is reduced, but the excessive heat may cause damage to the fixing device components
Solution Approach 1:
By making the conductive layer thinner in the heat generation portion compared to electrode portions, the film achieves concentrated heat generation exactly where needed for fixing toner images. This localized heat generation approach enables rapid warm-up while preventing excessive heat in electrode areas and surrounding components, thus avoiding heat damage without extending warm-up time
Solution Approach 2:
The film is segmented into distinct functional zones with different conductive layer thicknesses: electrode portions with thicker conductive layers for electrical connection and heat dissipation, and a heat generation portion with thinner conductive layer for controlled heat generation. This segmentation allows the film to achieve rapid heating while protecting other components from excessive heat
3Productivity
If the electrode portion has small surface area, then the device complexity is reduced, but the heat generation and fixing efficiency is insufficient
Solution Approach 1:
The conductive layer thickness is locally optimized: thicker in electrode portions to provide sufficient surface area for effective electrical contact and heat generation during the fixing process, while thinner in the heat generation portion to concentrate heat where needed. This local variation ensures high fixing efficiency without requiring uniformly complex structures throughout the entire film
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 configuration enhances heat efficiency, reduces warm-up time, and minimizes energy consumption by optimizing heat generation and distribution, ensuring effective fixing of toner images onto recording materials while preventing damage from excessive heat.
Implementation Method 1
A fixing device using this film causes the film to generate heat, utilizing joule heat. The fixing device causes generation of the Joule heat, by feeding an electric current to the heat generation portion by bringing an electrode member such as a conductive brush into contact with the electrode portion.
Data Source
AI summary
A film for use in a fixing device includes a base layer having a cylindrical shape. An electrode portion is formed at an end part of the base layer in a longitudinal direction of the film. A heat generation portion is formed at a central part of the base layer in the longitudinal direction of the film and electrically connected to the electrode portion. The heat generation portion is formed of a conductive layer made of a same material as a material of the electrode portion. A thickness of the conductive layer is larger in the electrode portion than in the heat generation portion. A surface area of the conductive layer per unit length in the longitudinal direction of the film is larger in the electrode portion than in the heat generation portion.