Heater Lamp Fixing Ultrafine Particle Emission
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Solution Overview
Problem
Image forming apparatuses, particularly those using electrophotographic processes, face challenges in meeting ecological standards due to excessive generation of ultrafine particles during the fixing process, which exceeds certification limits set by environmental marks like the Blue Angel mark, primarily attributed to the heater lamp for fixation.
Innovation Solution
A heater lamp for fixation is designed with a protective casing of quartz glass and a heat generator, where the amount of carbon on the external surface is reduced to 12 atomic % or less using X-ray photoelectron spectroscopy, and further cleaned and heated to minimize ultrafine particle generation, with preferred materials being chrome and tungsten, and inert gases like nitrogen or argon sealed within the glass tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a heater lamp for fixation is used in image forming apparatus, then the fixing process can be performed efficiently, but ultrafine particles are generated in excessive amounts exceeding certification limits
Solution Approach 1:
The patent changes the chemical composition parameters of the protective casing by controlling carbon content to 12 atomic% or less and sulfur content to 0.1 atomic% or less, thereby reducing ultrafine particle generation while maintaining fixing efficiency
Solution Approach 2:
The patent uses an inert gas atmosphere (nitrogen or argon) inside the protective casing to prevent oxidation and chemical reactions that would generate ultrafine particles, while still allowing the heat generator to function effectively for fixation
2Object-generated harmful factors
If the protective casing is made with specific material composition to reduce carbon, then ultrafine particle generation is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies precise compositional parameters for the protective casing material (carbon ≤12 atomic%, sulfur ≤0.1 atomic%) to control ultrafine particle generation, balancing environmental requirements with manufacturability
Solution Approach 2:
The patent uses X-ray photoelectron spectroscopy to detect and measure the carbon content on the external surface of the protective casing, providing a precise measurement method to verify compliance with the 12 atomic% carbon limit
3Object-generated harmful factors
If heating is applied to oxidize surface-bound components, then particle emission is reduced, but energy consumption increases
Solution Approach 1:
The patent applies heating to oxidize surface-bound components during the manufacturing process before the heater lamp is installed, thereby reducing particle emission during operation without requiring continuous energy input during the fixing process
Solution Approach 2:
The patent uses an inert gas atmosphere inside the protective casing to prevent oxidation of the heat generator and reduce particle emission, eliminating the need for continuous heating while maintaining low particle generation
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 significantly reduces ultrafine particle generation, allowing the image forming apparatus to meet the stringent certification standards for environmental marks by minimizing carbon-based contamination and oxidizing surface-bound components, thereby reducing particle emission.
Implementation Method 1
a heat generator; and a protective casing to cover the heat generator
Implementation Method 2
oxidizing surface-bound components, thereby reducing particle emission
Implementation Method 3
an amount of carbon in an external surface of the protective casing as detected by an X-ray photoelectron spectroscopic method
Data Source
AI summary
A heater lamp for fixation and a method of producing the heater lamp are provided. The heater lamp includes a heat generator and a protective casing to cover the heat generator, in which an amount of carbon in an external surface of the protective casing as detected by an X-ray photoelectron spectroscopic method is equal to or less than 12 atomic %. The method of producing a heater lamp for fixation includes preparing a heat generator; preparing a protective casing to cover the heat generator; and heating the heat generator in an atmosphere containing oxygen gas.