Fuser Heater Element Angled Features Prevent Paper Wrinkles
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Solution Overview
Problem
Conventional fuser assemblies cause wrinkling in paper substrates due to moisture absorption leading to wavy edges, resulting in non-parallel edges and corrugations when passed through the fusing nip, which leads to defective copies.
Innovation Solution
A heater element with laterally spaced-apart features positioned near the input edge, where the inner surfaces of these features are angled relative to the substrate path, creating laterally spaced-apart low-pressure contact areas to prevent the wavy edge from flattening and expanding, thus preventing wrinkle formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a conventional fusing nip compresses the substrate to flatten wavy edges, then the edge becomes flat, but the non-parallel outer edges cause stress reactions forming corrugations and wrinkles
Solution Approach 1:
The heater element is divided into multiple heating zones with independently controllable temperatures. This segmentation allows different regions of the substrate to be heated to different temperatures, enabling the wavy edges to be flattened while maintaining the parallelism of outer edges by applying appropriate thermal treatment to each segment.
Solution Approach 2:
Different regions of the heater element provide different thermal conditions - higher temperatures at edges to flatten wavy areas, and controlled temperatures in the center to maintain dimensional stability. This local differentiation of thermal properties resolves the contradiction between edge flatness and overall edge parallelism.
2Reliability
If the substrate is compressed uniformly through the fusing nip, then the toner image is fixed, but the wavy edges are pressed out causing non-parallel outer edges and wrinkle formation
Solution Approach 1:
The fusing process uses dynamic temperature control where the heater element temperature profile is adjusted during the fusing cycle. The edges are heated to higher temperatures initially to flatten wavy areas, then the temperature is modulated to prevent over-compression and wrinkle formation while ensuring complete toner fixation.
Solution Approach 2:
The temperature distribution across the heater element is changed from uniform to non-uniform, with elevated temperatures at the edges to address wavy areas. This parameter change allows the substrate edges to be treated differently from the center, fixing toner while preventing wrinkle formation in the wavy edge regions.
3Device complexity
If the heater element applies uniform heat and pressure, then the fusing process is simple, but the wavy edges expand causing non-parallel outer edges
Solution Approach 1:
The heater element is segmented into multiple zones with independent temperature control, allowing edge regions to be heated differently from the center. This segmentation enables the system to handle wavy edges appropriately while maintaining overall process simplicity through automated zone control.
Solution Approach 2:
The multi-zone heater element serves multiple functions: it flattens wavy edges, maintains parallelism of outer edges, and ensures complete toner fixation all within a single fusing operation. This universal design handles both simple and complex substrate conditions without requiring separate processing steps.
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
The angled features on the heater element ensure that the substrate is gripped at its outer edges while the center remains uncompressed, preventing corrugations and wrinkles, resulting in improved print quality by maintaining the substrate's original dimensions during the fusing process.
Implementation Method 1
A fuser assembly may include a heated roller and a backup roller forming a fusing trip through which the media passes. The toner image is fixed to the media by the application of heat and pressure in a fuser assembly.
Implementation Method 2
The angled features on the heater element ensure that the substrate is gripped at its outer edges while the center remains uncompressed, preventing corrugations and wrinkles
Data Source
AI summary
A heater element is provided adapted to heat a belt in a fuser assembly. The heater element comprises laterally spaced-apart first and second features. The first feature may have a first inner surface and the second feature may have a second inner surface facing the first inner surface. Preferably, at least a majority portion of at least one of the first and second inner surfaces is positioned at an oblique angle relative to a reference line extending substantially perpendicular to a path a substrate moves along as it passes through the fuser assembly.