Endless Fuser Belt with Segmented Rolls and Heat Pipe
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Solution Overview
Problem
Existing fuser assemblies in electrophotographic devices face challenges in achieving fast fusing speed, short warm-up time, good narrow media performance, long life, and low cost simultaneously, often compromising one requirement to meet another, such as using thinner belts for faster warm-up but sacrificing axial heat transfer and media performance, or enlarging components for faster speed but increasing warm-up time and cost.
Innovation Solution
A fuser assembly design featuring a first metal roll with a heat pipe, a second metal roll with a higher rated heating element, an endless fuser belt, and a backup roll with a lower rated heating element positioned between them, allowing for a wider fusing nip and effective heat distribution, which reduces overheating and extends the life of components while maintaining faster fusing speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the fuser belt is made thinner to achieve faster warm-up and first print times, then the warm-up time is reduced, but the axial heat transfer capability and narrow media performance deteriorate
Solution Approach 1:
The fuser assembly is segmented into two separate metal rolls (first and second metal rolls) positioned within the fuser belt, each capable of independent heat generation and heat transfer. This segmentation allows each roll to be optimized for specific functions: one roll focuses on rapid heating while the other ensures uniform heat distribution, particularly for narrow media, thereby resolving the contradiction between fast warm-up and reliable narrow media performance.
2Productivity
If the fusing nip is enlarged to achieve faster fusing speed, then the fusing speed increases, but the warm-up time and first copy time increase
Solution Approach 1:
The patent applies local quality by positioning two heating elements with different rated heating powers at different locations within the fuser assembly. The first heating element (higher power) is positioned to provide intense localized heating for rapid warm-up, while the second heating element (lower power) ensures uniform heat distribution across the enlarged fusing nip area. This localized differentiation allows the system to achieve both fast fusing speed and short warm-up time simultaneously.
3Productivity
If greater load is applied to the fusing nip to achieve faster fusing speed, then the fusing speed increases, but manufacturing costs increase due to more robust components
Solution Approach 1:
The patent replaces the mechanical approach of applying greater load with a thermal approach using two heating elements. Instead of increasing mechanical pressure to achieve faster fusing, the system uses the first heating element (with higher rated heating power) to generate intense heat that enables rapid fusing at moderate loads. This substitution of mechanical force with thermal energy allows fast fusing speed without requiring more robust, expensive mechanical components.
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 design enables faster fusing speeds, shorter warm-up times, and improved narrow media performance while reducing the total load and manufacturing costs, extending the life of the fuser belt and backup roll by effectively distributing excess heat and maintaining a lower fusing temperature.
Implementation Method 1
a first metal roll having a heat pipe disposed therein
Implementation Method 2
a second metal roll having a first heating element disposed therein which has a first rated heating power; a second heating element having a second rated heating power and disposed between the first and the second metal rolls
Data Source
AI summary
A fuser assembly comprising an endless fuser belt having positioned internally within a first metal roll having a heat pipe, a second metal roll having a first heating element, and a second heating element disposed between the first and the second metal rolls. The endless fuser belt is disposed proximate to a backup roll for forming a fusing nip therewith, wherein a rotation of the backup roll moves the fuser belt and rotates the first and the second metal rolls. The second metal roll is positioned upstream of the first metal roll relative to a media process direction. The first heating element has a rated heating power greater than the rated heating power of the second heating element.