Heater Conductor Width Segmentation for Short-Circuit Prevention
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Solution Overview
Problem
Conventional image heating devices face issues with temperature rise in non-paper passing regions, leading to potential damage, and the increased complexity of multiple temperature detecting elements on ceramic substrates results in problems like short-circuiting and poor voltage resistance due to conductor material incompatibility and spacing issues.
Innovation Solution
The solution involves a heater design with a substrate, a heating resistor, and multiple electric conductors, where first and second conductors have specific width variations to ensure partial overlap and maintain adequate spacing, reducing the risk of short-circuiting and migration while allowing for efficient temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple temperature detecting elements are provided on the heater to control temperature, then temperature control precision is improved, but the number of conductors increases and space between conductors decreases leading to short-circuiting and poor voltage resistance
Solution Approach 1:
The conductor group is divided into two subgroups: first conductors connecting to heating resistors and second conductors connecting to temperature detecting elements. This segmentation allows independent optimization of each conductor type's width and spacing, resolving the conflict between needing multiple conductors and maintaining adequate spacing.
Solution Approach 2:
Different conductor widths are assigned to different functional groups: first conductors have width W1 optimized for power transmission to heating resistors, while second conductors have width W3 optimized for signal transmission from temperature sensors. This local quality differentiation allows each conductor type to be optimized for its specific function while maintaining appropriate spacing.
2Reliability
If conductor width is reduced to ensure spacing between multiple conductors, then short-circuiting is prevented, but conductor current carrying capacity and voltage resistance decrease
Solution Approach 1:
The conductor system is segmented into first conductors with larger width W1 for high-power heating resistor connections and second conductors with optimized width W3 for temperature sensor connections. This segmentation allows each conductor type to have appropriate power capacity for its function while maintaining overall spacing reliability.
Solution Approach 2:
Different width specifications are applied locally to different conductor groups based on their functional requirements. First conductors use width W1 optimized for power transmission, while second conductors use width W3 optimized for signal transmission, ensuring each conductor has sufficient power capacity for its specific application.
3Reliability
If different conductor materials are used to ensure compatibility with different elements, then connection reliability is improved, but manufacturing complexity increases due to multiple material deposition processes
Solution Approach 1:
The conductor fabrication process is segmented into two separate deposition processes: one for first conductors (width W1) and one for second conductors (width W3). This segmentation allows each conductor type to be optimized for its specific material compatibility requirements while maintaining manageable manufacturing complexity through systematic multi-step fabrication.
4Area of stationary object
If heater size is reduced to improve apparatus compactness, then space utilization is improved, but conductor spacing becomes insufficient leading to migration and short-circuiting
Solution Approach 1:
The heater's conductor system is segmented into first and second conductors with differently optimized widths. This segmentation enables efficient space utilization by placing conductors with smaller width requirements (second conductors for temperature sensors) in regions where compact spacing is critical, while first conductors with larger widths are positioned where more space is available.
Solution Approach 2:
Different conductor width specifications are applied to different regions of the heater based on local spacing requirements. Second conductors connecting to temperature detecting elements use width W3 optimized for compact spacing, while first conductors use width W1 optimized for power transmission in regions with greater available space.
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 effectively reduces the size of the heater while preventing short-circuiting, migration, and poor voltage resistance between conductors, ensuring reliable temperature control and apparatus safety.
Implementation Method 1
a heating resistor provided on the substrate
Data Source
AI summary
A plurality of electric conductors provided on a substrate of a heater of an image heating device has a conductor group A including a plurality of first electric conductors and a conductor group B including a plurality of second electric conductors. The plurality of first electric conductors each have a first portion having a width W1 and a second portion having a width W2 smaller than the width W1, are provided on the substrate to be arranged side by side in a width direction. The plurality of second electric conductors each have a width W3 larger than the width W2, are provided on the substrate to be arranged side by side in a width direction so as to partially overlap the second portion.