Heater Electroconductive Line Width Optimization
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Solution Overview
Problem
Existing image heating apparatuses for fixing devices in image forming systems suffer from high electric power consumption due to inefficiencies in the heat generation process, particularly in the electroconductive line resistance, leading to reduced heat generation efficiency.
Innovation Solution
The design incorporates a heater with a heat generating element arranged in a longitudinal direction on a substrate, where the heat generating region can be selectively energized by switching off sections, and the electroconductive lines are optimized in width and thickness to minimize unnecessary heat generation and power consumption, with thicker lines for higher currents and thinner lines for lower currents to reduce overall electric power usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large number of heat generation resistors are connected in series with electroconductive lines, then the heat generation capacity increases, but the electric power consumption increases due to higher current flow through the electroconductive lines
Solution Approach 1:
The heater is divided into multiple independent heating sections, each with its own heat generation resistors and electroconductive lines. This segmentation allows selective activation of only the sections required for the current task, reducing overall power consumption while maintaining the ability to generate sufficient heat in the active sections.
Solution Approach 2:
The heater employs dynamic control of electroconductive lines through switching elements that can connect or disconnect specific lines based on the required heating width. This dynamic reconfiguration optimizes the circuit configuration for each operating condition, minimizing power consumption while achieving the necessary heat generation capacity.
2Adaptability or versatility
If the heater is designed to accommodate multiple heat generation resistors, then the heating coverage increases, but the structure becomes more complex
Solution Approach 1:
The heater structure is segmented into multiple standardized heating sections that can be independently controlled. Each section contains heat generation resistors arranged in a consistent pattern with associated electroconductive lines, creating a modular architecture that simplifies the overall design while providing versatile heating coverage.
Solution Approach 2:
The heater is designed with universal electroconductive line patterns that can serve multiple functions - acting as both power supply lines and switching control lines. The switching elements integrated into the electroconductive lines allow the same structural framework to accommodate different heating configurations for various sheet widths and heating requirements.
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 approach significantly reduces electric power consumption in the heater, enhancing energy efficiency and preventing unnecessary heat generation, thereby improving the overall performance of the image heating apparatus.
Implementation Method 1
a plurality of heat-generation resistors including positive resistance-temperature characteristics between two electro-conductive elements provided on a substrate along the lengthwise direction of the substrate are connected in parallel
Implementation Method 2
heat generating resistors having a positive temperature characteristic of resistance
Data Source
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AI summary
A heater includes: a substrate; a first electrical contact; second electrical contacts; first electrode portions and second electrode portions; heat generating portions; a first electroconductive line portion electrically connecting the first electrical contact and the first electrode portions; and a second electroconductive line portion electrically connecting one of the second electrical contacts and a part of the second electrode portions. A cross-sectional area of a portion, of the first electroconductive line portion, into which all of currents flowing through the first electrode portions merge when the currents flow from the first electrode portions toward the first electrical contact is larger than a cross-sectional area of a portion, of the second electroconductive line portion, into which all of currents flowing through the part of the second electrode portions merge when the currents flow from the part of the second electrode portions toward the one of second electrical contacts.