Self-Heating Fuser Roller Slit Design for Uniform Heat
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Solution Overview
Problem
Self-heating fuser rollers with cracks on the surface experience abnormal heat generation due to increased current density bypassing the cracks, leading to uneven heating and potential damage.
Innovation Solution
A self-heating fuser roller with a tubular resistor layer featuring slits that electrically isolate heat-generating portions, preventing current concentration at cracks and ensuring uniform heat distribution by arranging these portions in parallel and maintaining regular intervals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heater is provided inside the fuser roller, then heat fixing function is achieved, but the structure of the printer becomes complicated
Solution Approach 1:
The patent replaces the conventional heater (mechanical/thermal system) with a resistor layer that generates heat through electrical resistance. The resistor layer is formed by dispersing conductive particles in a resin layer, eliminating the need for separate heating elements and simplifying the overall structure while maintaining the heat fixing function
Solution Approach 2:
The patent uses composite materials by combining conductive particles (such as metal powder or carbon black) with resin materials to create a resistor layer. This composite structure enables the resin layer itself to function as a heating element, integrating the heating function directly into the fuser roller structure
2Device complexity
If electrically conductive particles are dispersed in a resin layer to create a self-heating fuser roller, then structure is simplified, but cracks on the surface cause abnormal heat generation due to increased current density
Solution Approach 1:
The patent divides the resistor layer into multiple independent segments by forming slits that extend in the axial direction. These slits partition the conductive particles into separate regions, preventing current from concentrating at crack locations and ensuring uniform heat distribution even when cracks are present
Solution Approach 2:
The patent preemptively addresses the crack problem by forming slits during the manufacturing process before the fuser roller is put into service. These pre-formed slits create intentional current interruption points that prevent abnormal current concentration that would otherwise occur at unexpected crack locations
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 solution effectively suppresses abnormal heat generation and ensures stable fixing by blocking current flow through cracks and maintaining uniform heat generation across the surface, enhancing the reliability and performance of the fuser roller.
Implementation Method 1
a tubular resistor layer that generates heat by being supplied with electricity
Data Source
AI summary
The present invention provides a self-heating fuser roller including a tubular resistor layer that generates heat by being supplied with electricity, in which the resistor layer has a plurality of slits. The slits are preferably disposed at regular intervals in a circumferential direction. The slits preferably extend in an axial direction. Preferably, the slits are not provided on both end edges in an axial direction. The slits preferably have an average width of 50 μm or more and 2 mm or less. The slits preferably have an average interval of 30 μm or more and 1 mm or less. The slits are preferably filled with a resin composition. The resistor layer preferably includes a resin matrix and a plurality of electrically conductive particles contained in the resin matrix.